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SP2.6 PV System Commissioning

How to commission solar properly and how to not brick your inverter!

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Wortenshire Oscar Weld
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234 views

SP2.6 PV System Commissioning

How to commission solar properly and how to not brick your inverter!

Uploaded by

Wortenshire Oscar Weld
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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PV System

Commissioning By Blake Gleason

PV is simple: Turn it on; have sun; make power.


Commissioning may seem like an unnecessarily

time-consuming and complex exercise, but it is a

critical part of a well-installed system.

U
nderstanding and paying attention to PV It keeps customers happy and minimizes callbacks. It ensures
commissioning is important to the industry. that a lot of silicon, aluminum, glass, steel, copper, dollars and
If the PV industry is to continue to expand effort are not wasted on nonperforming or underperforming
and become a significant part of the US systems. Commissioning guards against a lack of public con-
energy portfolio, short- and long-term sys- fidence in PV and renewable energy technologies.
tem performance is critical to maintaining This article covers the commissioning of both residen-
public confidence and goodwill. Already, tial and commercial scale grid-tied PV systems in detail.
many interested parties are making concerted efforts to Although it does not specifically address off-grid, battery-
maintain the quality control of installed systems. Power backup or vehicle PV systems, many of the same principles
Purchase Agreement (PPA) providers, for example, must apply. Similarly, while large utility scale PV systems are not
protect their investments; manufacturers want to see the specifically exemplified, the commercial scale procedures
PV market grow; and legislators and rebate administrators are easily scalable.
need to encourage responsible industry growth. Integrators,
who play such a large role in the story, must do their part THE BUILDING COMMISSIONING PROCESS
to ensure the safety, quality and performance of installed The commissioning process is typically applied to entire
PV systems. buildings. To set a framework for PV commissioning, it
Commissioning is a way to formalize quality control of is useful to examine the total building commissioning
installed PV systems. The process ensures that systems are process. The Building Commissioning Association (BCA)
safe and high performing. It encourages integrators to be defines commissioning in its sample specification as:
responsible for their installations and facilitates project “a quality-oriented process for achieving, verifying and
closeout and prompt payment. Successful commissioning documenting that the performance of facilities, systems
leads to satisfied installers, employers and system owners. and assemblies meet defined objectives and criteria. The
Satisfied customers become repeat customers and lead to commissioning process begins at project inception (dur-
sh aw ns ch rein er. co m

new clients. Seen in this light, commissioning is essential to ing the pre-design phase) and continues through the life of
the growth of the PV industry and to the overarching goal of the facility. The commissioning process includes specific
installing more renewable energy systems. tasks to be conducted during each phase in order to verify
Think this is an overstatement? Consider what commis- that design, construction and training meet the owner’s
sioning prevents. It protects against fires, shocks and injury. project requirements.”
solarprofessional.com | S O L A R PR O 35
PV System Commissioning

Further, the BCA outlines the basic tasks of commissioning: r &TUBCMJTIQFSGPSNBODFCFODINBSLT


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installed according to the contract documents,
manufacturer’s recommendations and industry SAFETY IN COMMISSIONING
accepted minimum standards. You should take the same safety precautions that you
r 7FSJGZUIBUJOTUBMMJOHDPOUSBDUPSTQFSGPSNBEFRVBUF use during PV installation when commissioning the sys-
operation checkout. tem. Fall protection, ladder safety, electrical safety, per-
r 7FSJGZBOEEPDVNFOUQSPQFSQFSGPSNBODFPG sonal protective equipment and common sense are all
equipment and systems. required. When commissioning personnel are not part
r 7FSJGZUIBUUIFPQFSBUJPOTBOENBJOUFOBODF 0.
 of the installation crew, they are not familiar with the
documentation left on-site is complete. hazards on a particular job site. They may not be familiar
r 7FSJGZUIBUUIFPXOFSTPQFSBUJOHQFSTPOOFMBSF with best practice construction safety C O N T I N U E D O N P A G E 3 8
adequately trained.

COMMISSIONING PV SYSTEMS Quality assurance Commissioning is a process that starts during predesign and
Typically, system owners have specific proceeds through PV system acceptance. Far more than an inverter start-up
goals in mind for their PV system. These sequence, commissioning documents the as-built condition of the system—like this
might include reducing electric bills installation by Sun Light & Power in Berkeley, CA—and ensures that the installation is
by a certain percentage, maximizing safe, durable and performing properly.
the power output from available roof
space or maximizing return on their PV
investment. These goals are known as
the owner’s project requirements. The PV
system designers then devise a strategy
to meet these requirements. This strat-
egy, including documents describing
the intended system components and
calculated expected performance out-
put, is called the basis of design, which
should help guide the PV commission-
ing process.
At the most basic level, commission-
ing ensures that the owner’s require-
NFOUT IBWF CFFO NFU .PTU PG UIF 17
system commissioning will occur after
installation is complete and before proj-
ect closeout. It should include the fol-
lowing elements:

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complete.
r 7FSJGZUIBUUIFJOTUBMMBUJPOJT
safe.
r 7FSJGZUIBUUIFJOTUBMMBUJPOJT
aesthetically acceptable.
r 7FSJGZUIBUBMMDPNQPOFOUTPG
sh aw ns c hrein er. co m

the installation are robust and


permanent.
r %PDVNFOUBTCVJMUDPOEJUJPOT
r 7FSJGZTZTUFNQFSGPSNBODF
r 7FSJGZQSPQFSTZTUFNPQFSBUJPO

36 S O L A R PR O | October/November 2009
PV System Commissioning

procedures. In that case, a qualified installer should be pres- and bid documents. Include required documentation, check-
ent and responsible for maintaining safe conditions during lists, testing procedures, expected performance and basis of
commissioning. All equipment inspections should be made design. It is also important to specify requirements for the
with both utility and solar electrical sources switched off commissioning timeline and give guidance on what person
and locked out. or entity will be responsible for the commissioning.
After inspections, the equipment is energized at commis- Timeline. Commissioning should be considered through-
sioning, often for the first time. Proper testing and planned out the course of a PV installation project. It should be
sequencing will ensure that neither equipment nor people planned for during the design phase, built into the system
are subject to destructive voltage or current. Be alert. If some- cost, actively carried out at the end of construction and
thing seems wrong or if unexpected phenomena result when repeated as desired after project completion. However,
energizing equipment—such as pops, bangs, smoke or sud- most of the commissioning work will occur just after the PV
den darkness—do not rush to try to “fix” the problem. Slow installation is complete and the system is ready to be turned
down; determine the cause; make sure no hazard is present; on for the first time.
and then determine the best course of action. If a ground fault This initial startup is often called commissioning the
is indicated or suspected, assume that all conductive surfaces system. Ideally, this commissioning event occurs after all
in the system present a shock hazard until testing determines permits are signed off; both permanent power and Internet
otherwise. (See “PV System Ground Faults,” August/Septem- are established at the site; the utility has given permission
ber 2009, SolarPro magazine for detailed information on to operate the system; and the monitoring system, if appli-
locating and troubleshooting ground faults.) cable, is operational. If one or more of these milestones is
delayed, you may want to start up and test the system regard-
COMMISSIONING PROCESS less. Final acceptance of the system may still be contingent
&TQFDJBMMZGPSMBSHFSQSPKFDUT EVSJOHUIFEFTJHOQIBTFDPN- on passing subsequent milestones, but you can verify sys-
missioning should be incorporated into the specifications UFNQFSGPSNBODFJOUIFNFBOUJNF0OF C O N T I N U E D O N P A G E 4 0

Recommissioning and
Retro-commissioning of
Existing Systems
Recommissioning. Repeating the commissioning of a sys- Retro-commissioning. For PV systems that were not
tem that was previously commissioned is called recommission- properly commissioned in the first place, all hope is not lost.
ing. Usually, recommissioning should be the last step in any Retro-commissioning can be performed at any point in the
substantial maintenance project, such as after replacing major system’s lifetime. Although commissioning is a good idea for
components, especially inverters; after adding additional mod- any system and is better done late than never, the addi-
ules; after a non–self-clearing alarm is diagnosed and repaired, tional expense of retro-commissioning may be best justified
such as a ground fault; and as part of a system checkup or whenever there is a significant concern that the system is
regular annual maintenance visit. underperforming. Several indications of possible underper-
In addition, if the original commissioning was performed formance include:
during less than optimal seasonal conditions, like shading t Monitoring system reports faults, alarms or low
or extended poor weather, a recommissioning event may be performance.
called for during better conditions or in the summer. Recom- t Utility bills are higher than expected, after taking into
missioning results should be closely compared to those from account any new loads.
the original commissioning. If the results are inconsistent t One inverter shows significantly less accumulated
(after accounting for shading or other changes), the system kWh than others, even though they all have the same
integrator should track down the source of the inconsisten- size arrays and no difference in shading.
cies. Recommissioning performance results should also be t Total accumulated kWh, read from the inverter, is
compared to updated expected performance numbers and significantly less than predicted for the relevant
discrepancies addressed. time period. X

38 S O L A R PR O | October/November 2009


   

 
 

 ' !
!"(!"#$#!$!
%# $!#!#$!
!%'!
#!#&#
!!$$
"'"#

 

 
 
PV System Commissioning

exception to this timeline is for systems


that have a “burn in” period, such as thin
film amorphous silicon systems. These
systems will experience a significant, but
expected, drop in production over the
first few weeks and months of operation.
Therefore, performance measurements
made at initial system startup will be arti-
ficially high. Recommissioning is required
after this burn-in period.
Be sure to schedule the commission-
ing as soon as possible after PV system
construction is complete, but within a
suitable window of weather. It does not
make sense, for example, to commission
when there is irradiance of less than
400 W/m2 in the array plane. Not only
must the weather be good, but the time
of day must also be appropriate.
&TQFDJBMMZ PO TNBMM QSPKFDUT  UIF
tendency is to try to commission the
system at the end of the last day of
installation. This strategy is efficient

s h aw n sc h re in e r. co m
CVUOPUFòFDUJWF0GUFO UIFTVOJTUPP
low in the sky to provide sufficient irra-
diance for proper performance verifi-
cation. Shading is also more likely at
the end of the day, and any shade on
the array makes performance verifi- Torque settings Before commissioning is complete, verify all torque settings. The
cation difficult. Finally, commission- author is shown here with a torque wrench verifying the compression of grounded
ing demands focus, clear thinking and dc current carrying conductors inside a Satcon inverter.
sufficient time. If the end of the day is
near, the crew may be cold, hot, hungry, &WFOUIPVHIUIFFOHJOFFSXPSLTGPSUIFJOUFHSBUPS IFPSTIF
thirsty or just ready to go home. None of these conditions are is at least one level removed from the physical project.
likely to produce accurate commissioning results. It is better At a bare minimum, a person with sufficient knowledge
to clean up, go home and come back another day when the about PV in general and the system being commissioned in
sun is out and minds are fresh. particular must undertake commissioning. This is true even for
Who does it? For commissioning to be most effective, the small residential projects, where the best person to commission
commissioning party should not be inclined towards a cur- might be the crew leader who was in charge of the installation.
sory process with a guaranteed positive outcome. The con- As someone with a supervisory role, the crew leader can dele-
tractor who installed the system will usually have this bias. gate any corrective tasks and focus on effective commissioning,
Ideally, the commissioning party should represent the system leaving behind a system to be proud of. Regardless of the level of
owner, not the installer, and should be able to act completely objectivity, whoever carries out the commissioning must have
in the owner’s interest without conflict. For large systems, the proper tools and sufficient training.
the owner should contract with an outside commissioning Documentation. The commissioning agent must start with
specialist to oversee the commissioning process. all of the available system documentation. Before undertak-
If the scope of the project is not sufficient to bring in an ing commissioning, relevant documentation such as the
outside specialist and a direct representative of the owner following must be on hand: drawings, ideally as-built; cut
is not available, commissioning should be performed by an sheets for modules and inverters; specifications, especially
objective party under the original system integration con- as they pertain to commissioning; special requirements or
tract. For small commercial projects, for example, an engi- forms for rebate programs or other incentives; and equip-
neer or system designer might be the best choice for the job. ment manuals. C O N T I N U E D O N P A G E 4 2

40 S O L A R PR O | October/November 2009
PV System Commissioning

The commissioning agent must also understand what elements and the environment it will be subjected to for the
deliverables are required at the end of the process. For a design life of the system, usually 30-plus years for PV sys-
municipal or federal PV project, for example, the deliver- tems. Fasteners should be stainless steel, and steel rack ele-
ables are often extensive and detailed in the bid package. NFOUTTIPVMECFIPUEJQQFEHBMWBOJ[FEPSCFUUFS%JTTJNJMBS
For a residential project, the commissioning documentation metals must be isolated to avoid galvanic corrosion. Wiring
may be part of a post-installation punch list that remains in and raceways must be suitable for their location. Sunlight
the customer file for internal use. resistant wire is required under arrays, for example, and
FMFDUSJDBM NFUBMMJD UVCJOH &.5
 JOUFSNFEJBUF NFUBM DPO-
COMMISSIONING TASKS EVJU *.$
PSSJHJENFUBMDPOEVJU 3.$
JTSFRVJSFEPOUIF
For a small PV system, commissioning might mean that SPPG .BLF TVSF UIBU NEC required labeling is present and
the installer takes a step back, looks over the installation, that it is made of appropriate materials, such as engraved
tests voltage at a few points, watches as everything turns on metal or plastic.
successfully and verifies system performance. At the other Document as-built conditions. %VSJOH UIF WJTVBM TZTUFN
extreme, for a large PV plant there might be a dedicated review, note anything out of the ordinary. C O N T I N U E D O N P A G E 4 4
commissioning team with a multi-day, multi-faceted com-
missioning agenda, including follow-up activities and writ- Photo document In addition to approving installation prac-
ten reports. Whatever the scale, and whoever does the com- tices, like proper conduit support spacing and the tightness
missioning, the basic tasks and goals of the process remain of conduit fittings, the commissioning agent should document
the same. the installation’s as-built condition with many photos.
Verify that the installation is complete. Are all components
permanently installed? Is everything wired completely? Per-
manent utility power should be connected at the site. In
addition, if Web based monitoring is being used, the Internet
DPOOFDUJPOTIPVMECFPQFSBUJPOBM&YBNJOFUIFNPTUSFDFOU
installation punch list to make sure all items are complete.
Verify that the installation is safe. Has the permit been
signed off ? Are the mechanical and structural systems ade-
quate and built according to plan? Has any required water-
proofing been completed satisfactorily? Has the electrical
design been adapted properly?
A few common problem areas are worth checking:

r .BLFTVSFXPSLJOHDMFBSBODFTBSFNBJOUBJOFE
r 7FSJGZUIBUBMMNFUBMMJDTVSGBDFTUIBUNJHIUCFDPNF
energized are grounded.
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field are as shown on the plans.

Verify that the installation is aesthetically acceptable. Check


to see that the PV array is only as visible as it was designed to
be. Verify that module lines are straight and parallel to roof
features, especially where visible from the ground or high
traffic areas. Is all other equipment installed plumb, level
and with good workmanship?
Are any required aesthetic treatments complete? If this
was part of the contract, for example, inspect whether con-
duit systems and disconnects are painted to match the walls.
s h awn s ch re in er.c o m

&OTVSF UIBU 17 BSSBZ TLJSUT  XIFSF SFRVJSFE  BSF JOTUBMMFE


and satisfactory. Check that inverter fences or enclosures
are built as designed.
Verify that the installation is robust and permanent. &OTVSF
that all outdoor equipment is designed to withstand the

42 S O L A R PR O | October/November 2009
R

Bright Thinking in Solar


PV System Commissioning

&BDI RVFTUJPOBCMF JUFN TIPVME CF XSJUUFO EPXO BOE QIP- rating of the system, the system location and the array orien-
tographed, with the photo location marked on a roof plan tation; monthly and annual kWh performance estimates are
or other appropriate drawing. Take pictures of all arrays, given as an output. The California Solar Initiative (CSI) rebate
ideally from at least two angles. Also take pictures of con- calculators are also available to the general public, although
duit runs, combiner boxes, disconnects, inverters and the they are of interest primarily to California utility customers.
interconnection. 'PSFYBNQMF UIF$4*&YQFDUFE1FSGPSNBODF#BTFE#VZEPXO
Verify that the module layout matches the approved roof &1##
 DBMDVMBUPS TFF 3FTPVSDFT
 BMMPXT GPS UIF JOQVU PG
plan drawing. Note any discrepancies on the drawing. Verify specific module and inverter combinations, monthly shad-
that the module string layout is as shown on the as-built ing data, as well as information about the site location and
string diagram, including consistency of wire and string array orientation. It does not, however, allow changing other
numbering. Accurate string diagrams are extremely help- assumptions such as module mismatch, wire losses and sys-
ful for future maintenance and troubleshooting. For smaller UFNBWBJMBCJMJUZ&1##VTFT178"554GPSJUTCBDLFOE
systems, if a string diagram does not exist, identify the string .BOZJOUFHSBUPST 11"QSPWJEFSTBOEUIJSEQBSUZTPGUXBSF
locations and document them on the roof plan. For large sys- developers provide performance calculators. Some products
tems missing a string layout, identify this as an action item available for purchase, like Clean Power Finance and Quick-
for the integrator. Quotes from Clean Power Research, include updated elec-
%PDVNFOUUIFNPEFMOVNCFSBOERVBOUJUZPGUIFNPE- trical rate schedules and other information not only to esti-
ules, inverters, combiner boxes, disconnects and monitor- mate PV production but also to provide detailed financial
ing system. analyses. Fortunately, for commissioning purposes, all that
you need are the power and energy output of the PV system.
EXPECTED PERFORMANCE Since all of the energy calculators are based on average
Probably the most difficult and the most important aspect historical weather data, a PV system should not be expected
of commissioning a PV system is evaluating whether it is to produce exactly the amount predicted by the energy cal-
performing as well as it should be. First, the expected per- culator in a given day, week or month. The longer the inter-
formance needs to be determined. Then, the actual perfor- val, the better the actual performance should match the pre-
mance needs to be measured. dicted performance. While there
To determine the expected per- is significant variation in weather
formance of the PV system, refer even from year to year, certainly
to the basis of design. Assuming after 5 or 10 years the system’s total
that the system was sized properly accumulated energy production
in the design phase, it should meet should match the predicted output.
the owner’s requirements for energy Unfortunately, 10 years is too long
production. Based on the equipment to wait to make sure the system is
specified, estimate the monthly, working as intended.
annual and lifetime energy output At initial system commission-
of the system. ing, very little historical produc-
.BOZTPGUXBSFQBDLBHFTBOE8FC tion data is available. Therefore, the
based calculators can simplify this single best metric to verify system
task. For example, you can use the performance in the short term is
free PVWATTS Web based calcula- the instantaneous power output of
tor to get a very quick energy harvest the system. The following process
estimate by inputting the peak dc is one way to estimate the expected
value of the system power output at
any moment.
Cell temperature An infrared ther- 1. Determine the peak dc power
mometer is often the easiest tool rating of the system. This value will
for measuring cell temperature. For be the sum of the power outputs of
s ha wn sc hrei ne r.c om

performance verification testing, ideal individual modules at STC.


average one set of cell temperature 0CUBJOJOH UIJT OVNCFS JT TUSBJHIU-
measurements at the beginning and forward, because it is the product of
another at the end of the perfor- the nameplate module rating (PSTC )
mance measurement period. and the total quantity of modules.

44 S O L A R PR O | October/November 2009
2. Calculate the irradiance factor,
KI. First, use a pyranometer to mea-
sure the actual irradiance in watts
per square meter. This measurement
1 Probably the most
difficult and the most
Shading = 1.0 If the array is shaded
at all, proper verification of per-
formance output is very difficult.
.BLF TVSF JU JT OPU TIBEFE EVSJOH
should be taken in the same plane as important aspect commissioning.
the modules, with the same azimuth System availability = 1.0 %VSJOH
BOE UJMU BOHMF %JWJEF UIF NFBTVSFE of commissioning a commissioning there is no need to
irradiance by the STC irradiance PV system is evaluating derate for availability; the system
(1000 W/m2) to obtain the irradi- must be operating (available) when
ance factor. whether it is performing taking power measurements.
3. Calculate the module cell temper- as well as it should be. Tracking efficiency = 1.0 Trackers
ature factor, KT. .FBTVSFUIFDFMMUFN- should be in perfect working order dur-
perature TC of the modules in Celsius First, the expected ing commissioning. Since irradiance
using a thermocouple, thermistor performance needs to values are taken in the module plane,
or infrared (IR) thermometer. Find this factor is irrelevant regardless.
the module temperature coefficient be determined. Then, Age = 1.0 A brand-new system
of power, CT, from the module data the actual performance has yet to experience any age related
sheet or module manufacturer. This degradation.
coefficient is typically in the range of needs to be measured. Typically, the resulting system
−0.003/°C to −0.005/°C for crystalline derating factor, the product of all
silicon modules. Then, calculate KT system derating subfactors, is approxi-
as follows: mately KS = 0.90.
5. Calculate expected system per-
KT = 1 + (CT × (TC − TSTC)) formance, PE. &BDI PG UIF GBDUPST
above—irradiance, cell temperature
The cell temperature factor usually represents a reduc- and system efficiency—adjusts the expected output of
tion in power from the STC rating of a module due to cell the system relative to the controlled STC power rating.
operating temperature well above STC temperature (25°C). The overall expected power output from the combination
4. Determine the system derating factor, KS. This factor is a of these calculated and measured factors is determined
product of all of the system efficiencies and miscellaneous as follows:
subfactors, including: module mismatch, inverter efficiency,
module soiling, module nameplate tolerance, wiring losses, PE = PSTC × KI × KT × KS
shading, system availability, tracking efficiency and age.
PVWATTS describes many of these factors and provides It is important to maintain perspective on the calculation
default values. For instantaneous power measurement at of this expected power output. For a given set of modules,
system commissioning, the following values are typical, the irradiance is by far the factor with the most variation. It
although module-dependent factors can vary substantially is imperative to get reliable irradiance measurements to cal-
between manufacturers: culate KI; otherwise, the power estimate will have so much
Module mismatch = 0.97 This is representative unless the uncertainty that all of the other factors become meaningless.
system uses individual module power point tracking devices, Assuming that shading is avoided, the system derating
such as microinverters or dc-to-dc power optimization factor, KS, usually varies by a few percentage points, at most.
devices, in which case the mismatch is eliminated and this The cell temperature factor, KT, is not very sensitive to moder-
subfactor becomes 1.0. ate changes in temperature. Assuming a module with a tem-
Inverter efficiency = 0.96 A value in the 0.94 to 0.96 range is perature coefficient of power CT = −0.004/°C, for example, a
typical for most modern high efficiency grid-tied inverters. relatively large cell temperature change of 10°C changes the
Module soiling = 1.0 Assuming the system being commis- cell temperature factor by only about 4%. The net effect on
sioned is brand-new, there is no need to derate for soiling. the power estimate is only a few percentage points if the IR
Module nameplate tolerance = 0.99 It is reasonable to use thermometer used to take cell temperature readings is not
0.99 or better for most high-quality module manufacturers. highly accurate. The same is true if the cells measured hap-
Wiring losses = 0.98 These include dc wiring losses and pen to be abnormally high or low by a few degrees, or even
connection losses up to the inverter, where instantaneous if the cell temperature is estimated based on a certain rise
power output measurements are usually made. above ambient temperature.

solarprofessional.com | S O L A R PR O 45
PV System Commissioning

The irradiance reading in the module plane, however, can depending on the type of racking and accessibility under the
easily vary from 400 W/m2 to 1200 W/m2. From the 800 W/m2 NPEVMFT  PGUFO IPNFSVO XJSJOH TIPVME CF .FHHFS UFTUFE
nominal terrestrial environment base value, irradiance in before the modules are installed. If problems are found, the
the plane of the array might change 50% in either direction. homerun wiring is completely accessible for examination
The effect of this range of irradiance on the net predicted and replacement. Also, after all of the homerun wiring checks
power output is also +/− 50%. Clearly, it would be unac- out, both module-to-module connections and module-to-
ceptable to look up at the sky and guess “bright,” “overcast” homerun connections can be made as the modules are placed,
or “hazy,” rather than taking an accurate in-plane irradi- as long as the inverter ends of the homeruns are safely termi-
BODF NFBTVSFNFOU 0O B SFTJEFOUJBM TZTUFN XJUI BT GFX BT OBUFEBOEMPDLFEPVU&WFOUIPVHI.FHHFSUFTUJOHJTUZQJDBMMZ
three paralleled strings, an entire string could be discon- carried out before the PV installation is complete and full com-
nected and the commissioning test might not catch it if the missioning can occur, the test results should be documented as
in-plane irradiance is not measured with precision. they are obtained to avoid the need to repeat testing later.
Measure Voc of each string. 0QFODJSDVJU WPMUBHF DBO CF
PERFORMANCE MEASUREMENTS measured only while the strings are independent of each
The second half of performance verification is comparing other and before they are combined. For small string invert-
the expected power output to the measured power output. ers, this may mean measuring Voc on the line side of the dc
After you have verified that all of the specified equipment disconnect, with the dc disconnect open. For larger invert-
was installed, you can measure and document the perfor- ers, it likely means measuring Voc on the line side of the
mance of that equipment and compare it to the expected fuseholders in the combiner boxes, with the fuses removed.
values. Personal protective equipment is mandatory. Several 0ODFUIFDPNCJOFSCPYGVTFTBSFJOTFSUFEPSUIFEDEJTDPO-
tests are mandatory prior to inverter start-up. After start-up, nect is closed in a system with no combiner box, all of the
you can capture measured power output and compare it to strings are combined in parallel. Therefore, they will all mea-
the expected performance. sure the same Voc, which is misleading when trying to verify
Megger test each homerun. Homerun wiring should be tested individual strings. Verifying individual string Voc measure-
with a megohm-meter before modules are connected. In fact, ments is the quickest way to ensure that C O N T I N U E D O N P A G E 4 8

Inverter start-up The sequence of steps required prior to inverter


start-up includes line-to-line, line-to-neutral and line-to-ground measure-
ments at the ac disconnect.

sh a wn sc hrein er.co m (2 )

Voltage measurements As evidenced by this


open-circuit voltage measurement, the same
personal protective equipment required for
building the PV system is required during
system commissioning.

46 S O L A R PR O | October/November 2009
PV System Commissioning

all strings have the same number of modules and the correct
polarity. After this is verified, replace the series fuses and
close the fuseholders.
Inverter startup sequence. After you have completed all the
visual inspections and confirmed the dc open-circuit string
voltages, the system can be started up. Always follow the
inverter manufacturer’s directions for initial startup. Typi-
cally, the steps will include the following:

r 7FSJGZBMMDPOOFDUJPOT
r 7FSJGZDPSSFDUBDWPMUBHFBUUIFBD
disconnect.
r 7FSJGZDPSSFDUEDWPMUBHFBOEQPMBSJUZBU
the dc disconnect(s).
r $MPTFUIFBDEJTDPOOFDU
r 7FSJGZDPSSFDUBDWPMUBHFBUUIFJOWFSUFS
ac terminals.
r $MPTFUIFEDEJTDPOOFDU T

r 7FSJGZEDWPMUBHFBOEQPMBSJUZBUUIF
inverter dc terminals.
r *GBQQMJDBCMF TXJUDIUIFJOWFSUFSi0/u

s h aw n sc h re in e r. co m
r 8BJUGPSUIFJOWFSUFSUPTUFQUISPVHI
its internal startup sequence.
r 0ODFUIFJOWFSUFSJTSVOOJOH XBJUBCPVU
15 minutes for internal temperatures
and power point tracking to stabilize.
Pyranometer readings For best results, measure irradiance
Measure Imp for each string. Before paying much attention and inverter ac output simultaneously. This is most easily
to the total inverter output, verify that each string is producing accomplished with two people. Alternatively, you can set the
approximately the same amount of current. At the combiner pyranometer up on a tripod near the inverter and align it to
box or another accessible location, use a dc clamp meter to match the azimuth and tilt angle of the modules.
measure the current in the ungrounded source circuit con-
ductor of each string. If weather conditions are consistent
during the testing and all strings are oriented with the same Using a clamp meter for current and a multi-meter for voltage,
azimuth and tilt angle, the measured current values should verify that the voltage, current and power displayed on the
be identical, or at least within about 0.1 A of each other. For inverter match the measured values. Ideally, an independent
systems with individual module monitoring, verify that all power meter is used for this purpose, since it can also verify
modules are producing the same power levels. QPXFSGBDUPSBOEPUIFSQPXFSRVBMJUZDPNQPOFOUT0ODFZPV
If one string has no current at all, check again to make sure have verified the inverter’s internal meter and display, you can
both homeruns and all module leads are plugged in. If one use the power readings displayed on the inverter for all subse-
string has lower current than the others, double-check to make quent power measurements and reporting.
sure that string is not partially shaded either by a distant tree,
a nearby person or the commissioning agent’s notebook rest- PERFORMANCE VERIFICATION
ing on one of its modules. If no shading is present, measure the After completing all of the commissioning tasks and per-
current on the grounded dc string conductor. If the current is formance measurements as described, it is time to measure
different on the grounded conductor and the ungrounded con- power performance and compare this to predicted values.
ductor of the same string, a ground fault is likely carrying the 0OMZ UISFF NFBTVSFNFOUT BSF OFDFTTBSZ DFMM UFNQFSBUVSF 
difference in current. For larger central inverters, the ground irradiance and inverter ac output.
fault current from a fraction of one string may not be enough to 0G UIF UISFF  DFMM UFNQFSBUVSF JT UIF NPTU TUBCMF  BOE
trip the detection circuitry or blow the fuse. ac output is less sensitive to changes in temperature than
Measure ac power output. If measured current on all strings changes in irradiance. Take one set of cell temperature mea-
checks out, it is time to verify the inverter ac power output. surements at the beginning and another at the end of the

48 S O L A R PR O | October/November 2009
performance measurement period. The
easiest tool to use for this purpose is an
IR thermometer. Use this instrument to
measure a few cell temperatures in dif-
1 It is imperative to get
reliable irradiance
measurements;
that what had been a completely
clear sky now had a couple of hard-
edged cumulous clouds. I had just
measured about a 10% increase in
ferent places on a module and in a variety irradiance and production from
of locations throughout the array. Write otherwise, the power the elusive edge-of-cloud effect.
down the average cell temperature in estimate will have With a full monitoring sys-
degrees Celsius. tem or portable datalogger, 15
Irradiance and inverter ac output must so much uncertainty minutes’ worth of averaged irra-
CFNFBTVSFETJNVMUBOFPVTMZ&WFOPOBSFM- that all other factors diance and ac output provide an
atively clear day, high clouds or haze can excellent simultaneous reading.
quickly change irradiance. Remember to become meaningless. However, even with a simple $150
look up at the sky periodically during test- pyranometer and the inverter dis-
ing. In one case, I was so focused on jump- play, you can obtain good results
ing back and forth between reading the with the following method:
inverter displays and getting the pyranometer lined up with Find a good location to place the pyranometer so that
the modules, I was surprised when I looked at the measure- it has exactly the same azimuth and tilt angle as the mod-
ments I had written down over a period of about 2 minutes. ules. Ideally, the instrument has a square edge or bracket
0OFJSSBEJBODFWBMVFXBTNVDIIJHIFSUIBOUIFPUIFSUXP"U and can be clamped or held in place on the corner of a mod-
first, I thought I must have written it down wrong or held the VMF UP FOTVSF BMJHONFOU .BLF TVSF UIF QZSBOPNFUFS EPFT
pyranometer at the wrong angle—pointing directly at the sun, not shade the modules. Alternatively, set the pyranometer
for example—but then I noticed that the inverter output was up on a tripod and carefully align it to match the azimuth
also much higher. Finally, I looked up at the sky and noticed and tilt angle of the modules. The tripod method requires

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solarprofessional.com | S O L A R PR O 49
PV System Commissioning

a compass and inclinometer, but it is


convenient if there is a sunny space
to set up the tripod near the inverter.
.BLF TVSF UIBU SFBEJOHT PO UIF
1 A simple comparison
of expected and
measured performance
and measured factors, the actual perfor-
mance should be within about 5% of the
expected performance.
Some of the necessary measuring and
pyranometer and inverter can be reporting can be automated or accom-
taken within a few seconds of each determines whether plished more easily by using an installed
other: either with two people and the system has been monitoring system, also known as a
phones, radios or shouting; or with EBUB BDRVJTJUJPO TZTUFN %"4
 0GUFO 
one person when inverters are near successfully commis- these systems report inverter ac power,
the pyranometer setup. sioned. The actual irradiance and module cell temperature.
Write down the pyranometer Some even measure and report individ-
reading in W/m2. performance should VBM TUSJOH PS NPEVMF PVUQVUT %VSJOH
Write down the inverter power be within about 5% initial system commissioning, however,
output in W or kW. UIF%"4NBZOPUCFQSPQFSMZDBMJCSBUFE
Repeat twice more, alternating of the expected or the network it relies on may not be set
back and forth between the pyra- performance. VQ 'VSUIFS  UIF %"4 SFQPSUJOH TIPVME
nometer and the inverter, for a total be verified by the on-site field measure-
of three alternated readings on each. ments previously described.
Alternating three times between the
two devices is a good approximation of “simultaneous” for CASE STUDY: 50 KWP COMMERCIAL SYSTEM, MULTIPLE
this type of measurement. INVERTERS
If the variation between readings is small, less than 2%, PV array capacity: 50,310 W STC; 234 SunPower SPR-215-
for both inverter and pyranometer, move on to the next WHT-U modules
inverter and array. If the variation is large, start again and Inverters: Six SunPower SPR-7000m and one SunPower
repeat the alternating readings until three consistent values SPR-4000m
are measured. Array installation: Thirty-six of the modules are on a much
Finally, average the three irradiance readings and the steeper roof plane than the others and are dedicated to
three inverter power readings. These are the values to use their own inverter.
when verifying performance. The system was originally commissioned, or partially
After you have calculated the expected performance and commissioned, just after construction was completed in the
measured the actual performance, a simple comparison helps middle of the winter. There was some midafternoon shading
you determine whether the system has been successfully on parts of the array that resulted in overall system perfor-
DPNNJTTJPOFE %FQFOEJOH PO UIF DFSUBJOUZ PG UIF BTTVNFE mance of about 5% below the expected, C O N T I N U E D O N P A G E 5 2

Table 1: Inverter Test Results


3/9/2009 Clear sky, no shading
Average Average
Inverter # Time Irradiance 1 Watts 1 Irradiance 2 Watts 2 Irradiance 3 Watts 3
irradiance watts
1 1:03pm 840 2,970 842 2,979 843 2,977 842 2,975

2 1:05pm 840 5,924 842 5,930 842 5,940 841 5,931

3 1:06pm 842 6,010 845 6,030 848 6,041 845 6,027

4 1:07pm 846 6,046 845 6,040 843 6,040 845 6,042

5 1:08pm 847 6,044 853 6,057 855 6,075 852 6,059

6 1:17pm 820 6,053 827 6,037 824 6,022 824 6,037

7 1:19pm 1,060 7,057 1,095 7,059 1,078 7,055 1,078 7,057

50 S O L A R PR O | October/November 2009
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PV System Commissioning

unshaded value. Because of the winter shad-


ing, the system was recommissioned 3 months
Table 2: Using the same methodology,
the temperature factor, KT, for
later, when the weather was clear and there System Derating Factor Inverter 7 is calculated as 0.935.
was no shade. However, there was slight mod- Wiring losses 0.98
System derating factor. Table 2
ule soiling after 3 months (module soiling fac- illustrates how this is calculated
UPSTFUUP
.VMUJQMFJSSBEJBODFBOEQPXFS Module soiling losses 0.99 using the appropriate subfactors.
readings were taken for each inverter, with Module mismatch 0.97
The system derating factor, KS, for
results summarized in Table 1 (p. 50). this system is calculated at 0.89.
Inverter 1 is the 4,000 W inverter with 18 Module nameplate Irradiance factor. The average
0.99
tolerance
modules, whereas the other six are 7,000 W recorded irradiance values, divided
inverters with 36 modules each. The 36 mod- Shading 1.00 by the STC reference value of 1000
ules on Inverter 7 are installed on a steeper W/m2, provide the system’s irradi-
Inverter efficiency 0.955
roof, which is clearly a great angle for the early ance factor, KI. For example, the
.BSDITVO BTTFFOCZUIFIJHIFSJSSBEJBODFJO Age 1.00 average irradiance during testing
that module plane and higher production on of Inverter 1 is listed in Table 1 as
System derating factor KS 0.89
that inverter. In addition, the 36 modules on 842 W/m2. The irradiance factor
the steeper roof plane receiving more irradi- for Inverter 1 is therefore 0.842 (842
ance were operating at a higher cell tempera- W/m2 ÷ 1,000 W/m2).
ture (42°C) than the other, lower-angle modules (35°C). The performance test results for this system are provided
Temperature factor. The temperature factor, KT, is calcu- in Table 3. Clearly, the system was performing quite well.
lated as follows: KT = 1 + (CT × (TC − TSTC)). In this case, the 0OHPJOHQFSGPSNBODFWFSJóDBUJPOJTTJNQMJóFETJODFUIFEBUB
temperature coefficient of power, CT, is −0.38 %/°C , as sup- acquisition system at the site monitors individual inverter
plied by the module manufacturer. production, as well as irradiance and cell temperature.
The measured cell temperature, CT, is 35°C for Inverters
1 through 6 and 42°C for Inverter 7. The STC reference tem- ESTABLISH PERFORMANCE BENCHMARKS
perature, TSTC, is 25°C. The temperature factor for Inverters 1 Another important function of commissioning is to establish
through 6 is therefore: performance benchmarks for the PV system. Carefully mea-
suring and documenting performance at the beginning of
KT = 1 + (CT × (TC − TSTC)) the system’s lifetime provides a standard to measure against
KT = 1 + (−0.38 %/°C × (35°C − 25°C)) during future maintenance. If the system appears to be per-
KT = 1 + (−0.38 %/°C × 10°C) forming well, follow-up measurements might not be taken
KT = 1 + (−0.038) until the next scheduled maintenance. For example, on a
KT = 0.962 residential system without continuous C O N T I N U E D O N P A G E 5 4

Table 3: Performance Test Results


Measured/
Quantity of STC watts Total STC System derating Irradiance Temp. factor Predicted Measured predicted
Inverter # modules per module watts factor (KS) factor (KI) (KT ) watts ac watts ac watts ac
1 18 215 3,870 0.89 0.84 0.962 2,789 2,975 107%

2 36 215 7,740 0.89 0.84 0.962 5,575 5,931 106%

3 36 215 7,740 0.89 0.85 0.962 5,600 6,027 108%

4 36 215 7,740 0.89 0.84 0.962 5,597 6,042 108%

5 36 215 7,740 0.89 0.85 0.962 5,644 6,059 107%

6 36 215 7,740 0.89 0.82 0.962 5,458 6,037 111%

7 36 215 7,740 0.89 1.08 0.935 6,941 7,057 102%

Total 234 215 50,310 — — — 37,667 40,129 107%

52 S O L A R PR O | October/November 2009
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PV System Commissioning

monitoring, the system owner can hang a clipboard


next to the inverter and write down the inverter out-
put at noon on the first sunny day of each month
or the first sunny weekend day. These numbers will
form a pattern over the years, and any drop in perfor-
NBODFDBOCFJEFOUJóFEBOEJOWFTUJHBUFE0GDPVSTF 
the initial numbers must meet expected values. If the
benchmark performance is unnecessarily low, the
system may never meet its expected performance
and no one will notice.
Similarly, after a year passes and system owners
receive the first “true-up” bill from the utility to find
they owe more than expected, they may point fingers
at the integrator. The integrator need only repeat
the measurements taken and documented the year
before at commissioning. If these match, the sys-
tem was undersized, or performance was overprom-
ised from the beginning, or the customer has added
loads that were not anticipated. Benchmark data is
particularly useful in this scenario, especially if the
customer formally accepted the results at the initial
commissioning.

ACCEPTANCE / CERTIFICATION

s h a wn s ch re in e r. co m
Various parties have varying degrees of interest in
accepting the PV system. In fact, one of the reasons
to perform commissioning is to fulfill acceptance test
requirements. Typical acceptance tests include:
%PFTUIF17TZTUFNPQFSBUFJOOPSNBMHSJEUJFNPEF
when presented with normal operating conditions, such
as in the presence of sun and utility power? Performance verification After measuring cell temperature, irradi-
Is the ratio of measured system power output to pre- ance and inverter output power, the author uses a laptop to verify that
dicted power output of the system at least 0.95? system performance is within 5% of expected values.
.PTU MPDBM KVSJTEJDUJPOT XJMM OPU DIFDL UP NBLF
sure the PV system performs as designed. As with the The owner will count on the system to produce the expected
NEC and most building codes, the AHJ’s main concern is that power for several decades. If the owner is a PPA provider, it
UIFTZTUFNJTTBGF0GUFO UIFQFSNJUJTTJHOFEPòCFGPSFUIF usually requires very strict acceptance testing. Funding of
system is ever turned on. the project, and the next project, is highly dependent on the
Similarly, most utilities are satisfied if the system design power produced from the system. The original PPA owner
passes the engineering review and the proper disconnects are may own the system for only 5 years, at which point it must
PCTFSWFE BU JOTQFDUJPO 0DDBTJPOBMMZ  UIF VUJMJUZ XJMM SFRVJSF be demonstrably in good working order so that the “fair
that automatic shutdown of the inverter upon grid failure be market value” buyout price remains as high as possible.
demonstrated. But a utility is rarely concerned with the mea-
sured power production values of the system. TRAINING
The PV integrator installing the system should be the As part of the commissioning process, the PV integrator
first to pay attention to the initial system production. From should train the owner on basic system operation. This
JOTUBMMFST UP TZTUFN EFTJHOFST UP DPNQBOZ $&0T  QSJEF JO training should include a physical walkthrough of the
their final product is linked to kilowatt-hour production. entire system, especially noting disconnect locations and
The integrator should not internally accept the installation procedures. Inverter operation should also be reviewed,
until proper operation and production is verified. including any display screens and status lights. Signifi-
Naturally, the system owner is the party with the most cant time should be dedicated to studying the monitoring
interest in accepting the newly commissioned PV system. system, if one is installed. The owner C O N T I N U E D O N P A G E 5 6

54 S O L A R PR O | October/November 2009
PV System Commissioning

Commissioning forms Keep completed commissioning to three credit points towards certification. For many
checklists and forms for internal use. The system owner OFXDPNNFSDJBMCVJMEJOHTXJUI17 -&&%DFSUJGJDBUJPOJT
may also require these as part of the O&M or acceptance a big deal. The PV commissioning agent needs to coordi-
documentation. OBUFXJUIUIF-&&%CVJMEJOHDPNNJTTJPOJOHBVUIPSJUZUP
ensure proper documentation.
Although rebate programs vary from state to state and
even from city to city, most require an upfront prediction
of system performance, upon which rebate dollar amounts
BSF CBTFE *O $BMJGPSOJB  UIF &YQFDUFE 1FSGPSNBODFm#BTFE
Buydown rebate is based entirely on the expected perfor-
mance, as the name implies. However, for larger systems—
currently systems over 50 kW, but in 2010 everything over
L8‡UIFSFCBUFJTFOUJSFMZCBTFEPOQFSGPSNBODF&OFSHZ
production is metered and rebates are paid based on kWh
production. Clearly, the system owner or other entity receiv-
ing the rebate money has a large incentive to ensure that
the system performs as expected. Similarly, the New Solar
Homes Partnership rebate amount is based on expected
performance, but actual payment is granted only after for-
mal system acceptance. For acceptance, site temperature
and irradiance measurements are required. The inverter-
s h a w n s c h re in er. c o m

displayed power output must match the expected power out-


put calculated for the measured irradiance and temperature
values. In addition, several markets have recently adopted
feed-in tariffs to stimulate PV installations.
The overall trend is clear. As performance based incen-
tives and feed-in tariffs become more popular in the US,
should be clear on how to access the monitoring system system owners will demand—and integrators will need to
display. The owner will need the URLs and passwords if the provide—excellent commissioning and performance verifi-
%"4JT8FCCBTFE BOEXJMMOFFEUPLOPXIPXUPOBWJHBUF cation services.
that display, how often to look at it, what to look for and
how to interpret alarms. Special thanks to Sun Light & Power for arranging site
The integrator and owner should also review all system access for project photography included with this article.
EPDVNFOUBUJPO JODMVEJOH0.NBOVBMTBOEXBSSBOUJFT*G
a maintenance contract is included, the scope of the con- 6 WEB E XCL USI VE GO TO SOLARPROFESSIONAL.COM/WEBEXCLUSIVE
tract should be reviewed and the schedule and first mainte- FOR THE FOLLOWING SAMPLE, DOWNLOADABLE DOCUMENTS: PRECOMMISSIONING
nance visit should be agreed upon. CHECKLIST, COMMISSIONING FLOWCHART, PERFORMANCE VERIFICATION FORM.

INCREASING EMPHASIS ON COMMISSIONING D


C O N TAC T
0UIFS CFOFGJUT UP UIF PXOFS PG DPNNJTTJPOFE 17 TZT-
Blake Gleason / Sun Light & Power / Berkeley, CA /
tems come from acceptance, recognition and financial
[email protected] / sunlightandpower.com
awards from third parties such as green-building certifi-
cation organizations and rebate administration agencies.
'PSFYBNQMF POFPGUIFQSFSFRVJTJUFTGPSUIF&OFSHZBOE Resources:
"UNPTQIFSFDSFEJUDBUFHPSZGPS-FBEFSTIJQJO&OFSHZBOE Building Commissioning Association / bcxa.org (Sample commissioning
&OWJSPONFOUBM %FTJHO -&&%
 DFSUJGJDBUJPO JT UIF DPN- requirements at: tinyurl.com/mrbw68)
missioning of all building energy systems, including the Clean Power Finance / cleanpowerfinance.com
PV system. Further, PV system commissioning explicitly Clean Power Research / cleanpower.com
requires performance verification. In other words, if the EPBB rebate calculator / csi-epbb.com
PV system performance is not verified, the building is not LEED / usgbc.org
FMJHJCMF GPS  PG UIF UPUBM BWBJMBCMF -&&% QPJOUT 0ODF PVWATTS / nrel.gov/rredc/PVWATTS
performance is verified, the PV system itself can earn up

56 S O L A R PR O | October/November 2009

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