SECTION 48 14 14 SOLAR PHOTOVOLTAIC (PV) POWER GENERATION SYSTEM PART 1 GENERAL 1.1 SECTION INCLUDES The work of this section consists of furnishing a complete Solar Photovoltaic (PV) Power Generation System interconnected with the utility grid at the Joliet Army Reserve site in Elwood, IL. 1.2 REFERENCESS The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. UNDERWRITERS LABORATORIES (UL) UL 969 (1995; Rev thru Nov 2008) Marking and Labeling Systems 1.3 ADDITIONAL REFERENCES IEEE 1547: IEEE Standard for Interconnecting Distributed Resources with Electric Power Systems IEEE 1547.1: IEEE Standard Conformance Test Procedures for Equipment Interconnecting Distributed Resources with Electric Power Systems IEEE 1547.2: IEEE Application Guide for IEEE Std 1547, IEEE Standard for Interconnecting Distributed Resources with Electric Power Systems UL 1703: Standard for Flat-Plate Photovoltaic Modules and Panels UL 1741: Standard for Inverters, Converters, Controllers and Interconnection System Equipment for Use with Distributed Energy Resources NEC: National Electrical Code 1.4 DEFINITIONS Array Rack Support Framing: Components provided by the PV contractor to mount equipment to the structure. NABCEP: North American Board of Certified Energy Practioners. Performance Factor: The total annual electric generation in the first year of operation divided by the system's capacity in kw under standard test conditions (STC) further divided by the number of peak sun hours per year. PV: Photovoltaic. STC: Standard Test Conditions SECTION 48 14 14 Page 1
1.5 SYSTEM REQUIREMENTS Provide one ground mounted solar photovoltaic power generation calculated to produce for 150,000 kwh/year. It is to include PV panels, inverter, and associated balance-of-system (BOS) components including wiring, conduit, disconnects, combiner boxes, overcurrent devices, surge suppression and grounding equipment, load sub panels, monitoring, metering equipment, support structure, and foundations. The PV power systems shall be installed as such, and must be capable of operation interconnected in parallel with the utility supplied electrical service to the facility. Pending approval by the utility, system will be interconnected with the utility grid. After approval from the utility, the system programming shall be configured to operate the system in parallel with the utility grid, allowing PV array energy to power on site loads directly from the inverter, and send any excess energy back to the utility grid. The equipment required, the desired system configuration, and the interfaces with other components and the project's electrical service are identified on the drawing sheets. Basis of design for this project are the products shown in PHOTOVOLTAIC PANELS and INVERTER sections in Part 2 of this specification section using a performance factor of 0.77. Contractor is in no way bound to the basis of design products listed in this specification section unless noted otherwise. Acceptable ranges of derate values for performance factor may be found at http://rredc.nrel.gov/solar/calculators/pvwatts/derate.cgi unless noted otherwise. The "Overall DC to AC derate factor" shown on the preceding website is synonymous to performance factor. Inverter and transformer derate values may use the California Energy Code weighted efficiency, but not a peak efficiency listed on manufacturer cut sheets. DC wiring from the panel to the inverter shall have a voltage rise (not voltage drop) at the panels of no greater than 2%. The inverter output circuit shall have a voltage rise (not voltage drop) of no greater than 1.5%. Photovoltaic panels shall be arranged to not shade any other photovoltaic panels at December 21 at 9 a.m. or 2 p.m., whichever results in the larget shadow. If contractor provides equipment other than the basis of design equipment included herein, the contractor must provide a system designed around those equipment components so that the system provides an equivalent or greater energy production. Items to consider include, but are not limited to, the number of panels per photovoltaic source circuit (also known as a string) matching the low voltage of the maximum power point tracking range of the inverter selected; locations of DC combiner boxes; system performance factor; and locations, quantities, and style of support system. Coordinate the design with the building electrical system, the electric utility, other disciplines, the Government, and all other parties involved to produce an IEEE 1547 and National Electrical Code compliant system. 1.5.1 Equipment Requirements The PV power system designs supplied for this project must have a design review and approval from the utility company. Contact Stephan Gunder at SECTION 48 14 14 Page 2
ComEd at 815-467-3628. Criteria for system approvals are based on applicable codes and standards, and consistency with industry accepted design practices. Evidence to support these criteria must be contained in the supplier's System Manual, which shall include all applicable information concerning the equipment and installation. 1.6 SUBMITTALS Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES: SD-02 Shop Drawings Shop Drawings; G, AE Indicate manufactured assembly's system and control schematics, solar panel installation, layout, weights, mounting and support details, and conduit and junction box connections. Support structure and foundation shop drawings shall be certified by a registered structural engineer. SD-03 Product Data Product Data; G, AE Submit data on specialties, including manufacturers catalog information. Submit performance ratings for solar panels and inverter. Submit data for approval on the solar panels, inverter, panel rack support system, combiner boxes, DC disconnect, meter and monitoring system. SD-07 Certificates Confined space entry permits SD-08 Manufacturer's Instructions Material Safety Data Submit mounting and other connection requirements. SD-10 Operation and Maintenance Data Spare parts lists and procedures SD-11 Closeout Submittals As-built drawings; G 1.7 REPLACEMENT AND SPARE PARTS All system components must be clearly specified as to the type, manufacturer, and model number for later needs for replacement and service as required, and documented in the System Manual. Sources for this SECTION 48 14 14 Page 3
equipment should also be identified. It is highly recommended that the supplier/installer either maintain or have a ready source for replacement components as needed for required warranties or service. 1.8 QUALITY ASSURANCE All products that are listed, tested, identified, and labeled by UL, CSA, ETL, or other National Testing Organization shall be used. Non-listed products or products that have not completed testing certification are not permitted. 1.8.1 Qualifications Manufacturer Qualifications: Company specializing in manufacturing products specified in this section with minimum three years documented experience. Installer Qualifications: Installer specializing in performing work of this section with minimum three years documented experience and trained by manufacturer, or the installer shall be NABCEP certified. 1.9 DELIVERY, STORAGE, AND HANDLING Accept and store solar panels in shipping containers until installation. Store in a dry location. Deliver, assemble, and install the equipment. 1.10 PROJECT CONDITIONS 1.10.1 Existing Conditions Verify field measurements prior to fabrication. 1.11 WARRANTY The supplier/installer must provide warranties on both the complete system and individual components. The methods for implementing a warranty provision must be clearly established, and handled by the system supplier/installer as the single point-of-contact for warranty service with the end-user. At a minimum, the following warranties are required: 1. PV panels must have a minimum 20-year limited manufacturer's warranty to maintain at least 80 percent of their initial rated output. 2. 10-year warranty on all other materials and workmanship. PART 2 PRODUCTS 2.1 PHOTOVOLTAIC PANELS General: Panels shall be UL listed, high-power type, and shall have a power tolerance between -3 percent and +5 percent, under Standard Test Conditions. The PV panels used in these systems must meet industry-accepted standards for performance, reliability, safety and other considerations as outlined SECTION 48 14 14 Page 4
below: 1. All PV panels shall meet or exceed the requirements of UL 1703 or equivalent standards. 2. Either crystalline or polycrystalline silicon flat-plate photovoltaic panel. 3. Manufacturers: Schott solar Poly, 230 watt under STC. 2.2 INVERTER Each system shall include an inverter as described below and where located on the drawings. The inverter shall be designed to be capable of automatic and continuous operation while connected in parallel with the electric utility service to the site. A. Subject to compliance with requirements, products that may be incorporated into the work are offered by, but are not limited to, the following manufacturer: 1. Manufacturer: PV Powered PVP75KW; PVP50KW. Following are other specific requirements for the inverter sub-system and components. Inverters shall: a. Be compliant with IEEE 1547 and be listed to UL 1741 by a recognized conformity assessment laboratory. Any ancillary equipment or modifications of inverter hardware required to install the inverter in parallel with the utility grid to meet the above standards must be provided with the inverter. b. Utilize maximum power point tracking to harvest the most energy from the PV Array. c. Be capable of being loaded to at least 150% on the input side. (Array STC watts divided by continuous AC watts of inverter, less than or equal to 150 percent.) d. Utilize a method of anti-islanding that requires no separate connections from the point of common coupling. Provide the following with the inverters: 2.3 METERS 1. LCD meter displays indicating system performance. 2. Remote communications SNMP/RS232 to internal network. 3. SP, polyphaser coax surge protector at the inverter on the AC side. 4. AC fault alarm relay connected to the monitoring system. Provide revenue grade Interval Data Recording (IDR) meters complete with industry standard telemetry for communication with Ethernet, cellular, or other common output capabilities. Meters must connect to a monitoring/data collection recording solar SECTION 48 14 14 Page 5
production through Time of Use (TOU) increments applicable to the local utility standards, with a minimum 15 minute intervals. 2.4 ELECTRICAL CHARACTERISTICS AND COMPONENTS Disconnect Switch: 1. Lockable. 2. Ampere rating as indicated on the drawings. 3. UL listed. 4. Utility approved. DC Array Combiner Box 1. All-weather enclosure (NEMA 3R or NEMA 4) suitable for exterior location. Electric Power Requirements: 1. Voltage provided must be compatible with the onsite distribution system. 2. The balance of the system (wiring, components, conduits, and connections) must be suited for conditions for which they are to be installed. Inverters shall use all-weather enclosures (NEMA 3R or NEMA 4) suitable for exterior location. An interval data meter must be installed to measure the AC output of the inverter. This meter should be located in close proximity to the billing meter and in a location accessible to Army Reserve facilities personnel. 2.5 ARRAY RACK SUPPORT FRAMING SYSTEM HARDWARE DESIGN AND INSTALLATION All hardware required for installing PV arrays and other system equipment must be provided for the installations. Following are requirements for mounting the PV arrays, equipment and other materials and mechanical design considerations associated with these projects: 1. A universal mounting array rack support framing system is required. Support framing hardware mounting systems must be adaptable to the various types of structural materials at this site. 2. The array mounting systems and overall installation must meet all applicable local building codes, and be capable of withstanding seismic forces and uplifting from wind forces for all attachment points, consistent with the panel manufacturer's installation instructions and the requirements of ANSI/ASCE 7-98. 3. The system installation and equipment layout should be considered with respect to the need for future maintenance of the PV arrays. 4. Minimize the risk from exposed fasteners, sharp edges, and potential damage to the panels or support structure. Corrosion resistance and durability of the mechanical hardware is required. Particular attention shall be given to the prevention of corrosion at the connections between dissimilar metals. The use of ferrous metals, galvanized material, contact of dissimilar metals without proper connection separation and the use of any wood or plastic components are not permitted. Aluminum and stainless steel components and hardware are required. SECTION 48 14 14 Page 6
5. The array layout should be consistent with the electrical ordering (and labeling) of source circuits in the array combiner boxes. 6. A minimum of 6-inch spacing shall be maintained between the panel frame and any solid surface to allow airflow to the backs of the PV panels. 2.6 GENERAL REQUIREMENTS: MARKING CONTENT AND FORMAT Marking: PV Systems shall be marked. Marking is required to provide emergency responders with appropriate warning and guidance with respect to isolating the solar electric system. Materials used for marking shall be weather and sunlight resistant. UL 969 shall be used as a standard for weather rating (UL listing of markings is not required). Main Service Disconnect: If the main service disconnect is operable with the service panel closed, then the marking should be placed on the outside cover. The marking shall be placed adjacent to the main service disconnect in a location clearly visible from the location where the lever is operated. Marking content and format: 1. Marking Content: CAUTION: SOLAR ELECTRIC SYSTEM CONNECTED a. Red background. b. White lettering. c. Minimum 3/8 inch letter height. d. All capital letters. e. Arial or similar font, non-bold. 2. Marking DC circuit a. Marking is required on all interior and exterior DC conduits, raceways, enclosures, cable assemblies, junction boxes, etc., in accordance with the National Electrical Code. b. Marking Content and Format Marking Content: CAUTION: SOLAR CIRCUIT. c. Red background. d. White lettering. e. Minimum 3/8 inch letter height. f. All capital letters. g. Arial or similar font, non-bold. 3. Inverters: Provide markings in accordance with the National Electrical Code. SECTION 48 14 14 Page 7
PART 3 EXECUTION 3.1 INSTALLATION Install in accordance with manufacturers recommendations, applicable codes listed under QUALITY ASSURANCE. 3.1.1 Electrical Design and Installation Requirements Following are specific electrical requirements for these systems and installations: 1. Inverters, controllers and PV panels must have specific listings as noted elsewhere in this document. All circuit breakers, fuses and disconnects must be listed for use in DC circuits where applicable. Equipment only rated for use in AC circuits will not be permitted for use in DC circuits. 2. All wiring (conductors) must be properly sized and rated for the application in accordance with the National Electrical Code. 3. All terminations must use listed box terminal or compression type connections, and must be made within an appropriate junction box or enclosure. Exposed, field splices between conductors will not be permitted. Twist on wire splices, crimped, soldered or taped connections are not permitted for the required field installed wiring of DC circuits. Proper torque specifications should be provided for all of the required field connections, and all termination points should be liberally coated with an anti-corrosion spray to preserve the quality of all connections over time. 4. All system conductors must have appropriate means for disconnecting and overcurrent protection. All overcurrent devices shall be sized in accordance with the National Electrical Code. 5. All series connected strings of panels (source circuits) must include a series fuse as required by NEC to prevent excessive reverse current flow through panels in source circuits under fault conditions, and the diodes must be contained in a listed junction/combiner box. Blocking diodes for array source circuits are required. These diodes must have voltage and current ratings (at temperature) at least twice the open-circuit voltage and short-circuit ratings of the source circuits. 6. All metallic panel frames, panel/array support structures, metal enclosures, and the inverter cabinets must be properly bonded to a common grounding conductor and terminate at a ground rod installed at the utility service entrance point. All grounding connections and terminations should be made accessible for routine inspections and maintenance as required. The neutral conductor of the inverter output shall be grounded at the customer's electrical service panel. No other AC connections to the grounding system are required. 7. Surge suppression on the DC and AC side of the inverter must be provided. Silicon oxide varistors (SOVs) commonly used to protect electrical panels and equipment may be used for this purpose, and may be provided and/or required by the inverter manufacturer. 8. An array ground-fault protection device must be included for all DC SECTION 48 14 14 Page 8
systems on the PV output circuit side of the inverter. This device protects the array from creating a fire hazard under fault conditions, and it must be capable of detecting array ground faults, shunting the fault current to ground, and disabling the array until the fault has been cleared. 9. All electrical equipment, enclosures, disconnects and overcurrent devices must be clearly marked and identified. 10. A PV panel indicated as "Spare panel" on the drawings shall be installed with its connectors short circuited. Spare panels' ungrounded conductors shall not be connected to other PV panels or any other part of the PV system. Except as noted in this item, spare panels shall be installed as specified in this specification section. 3.2 FIELD QUALITY CONTROL 3.2.1 Tests Performance monitoring will be verified by the metering installed on the system, recorded by the customer on a monthly basis. Based on these data and the size of systems installed, determinations can be made as to whether the systems are functioning properly, or whether any problems exist that require attention by the owner or service visit by the installer at a later date. 3.2.2 Inspections Inspections by agencies: 1. Required inspections shall be scheduled by the Contractor after notifying the Contracting Officer's Representative. 2. The utility company shall be contacted for approval prior to installation. Notify the Contracting Officer's Representative when contact has been made. After receiving final inspection approval for all related permits, the Utility shall be notified to inspect and provide the authorization to operate prior to the Contractor energizing the system. 3.2.3 Training The Contractor also will be required to provide a minimum of four hours of training to the end user and operator of each system. Topics to be covered in this training include theory of operation, operating requirements, component descriptions and specifications, maintenance requirements and schedule, safety precautions, overview of system manual, and record keeping. 3.3 PERFORMANCE MONITORING Performance monitoring will be verified by the metering installed on the system, recorded by the user on a monthly basis. Based on the data and the size of systems installed, determinations can be made as to whether the systems are functioning properly, or whether any problems exist that require attention by the user or service visit by the installer at a later date. SECTION 48 14 14 Page 9
3.4 COMPONENT REPLACEMENT Components with factory defects or defects due to installation shall be replaced at contractor's expense. Defects include but are not limited to the following: 1. Scrapes and scratches to panel encapsulant. 2. Any installation practice resulting in a voided warranty even if the component remains operational. For example, connecting polarized DC cables to the inverter in reverse. 3. Scrapes, scratches, or cracks in panel glass. -- End of Section -- SECTION 48 14 14 Page 10