Westinghouse AC System Installation Manual

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AC System Installation Guide

V2 60 Cell Modules

Rev: 10-12-11

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Page 1 AC System Installation Guide V2 60 Cell Modules Rev: 10-12-11...
Page 2 Section 107 or 108 of the 1976 U.S. Copyright Act, without prior written permission from an officer of Westinghouse Solar. For permission contact: Westinghouse Solar, 1475 South Bascom Ave. Suite 101, Campbell, CA 95008, Attn: VP of Marketing.
Page 3: Table Of Contents
Westinghouse Solar Roof Layout Site Surveys .................. 7 Drafting a Roof Layout ........................7 Elements of Designing a Solar System Specific to Westinghouse Solar AC Panels......8 Westinghouse Solar Mounting and Structural Requirements ............10 Drafting a Solar Array ........................12 Section III.
Page 4 Westinghouse Solar AC Installation Guide Grounding ............................29 Adding AC Interconnect Parts ......................30 Commissioning Westinghouse Solar AC Systems ................31 Section V. Westinghouse Solar Operations ..................33 Troubleshooting ..........................33 Troubleshooting an Inoperable Inverter (For Experienced Installers) ..........34 Disconnecting the Inverter from the PV Panel ................
Page 5: Section I. Getting Started
Section I. Getting Started 1. Safety Precautions • Before installing the Westinghouse Solar AC Module, read all instructions and cautionary markings in the Westinghouse Solar AC documentation. • Perform all electrical installations in accordance with all local electrical codes, the National Electrical Code (NEC), ANSI/NFPA 70 and local utility requirements.
Page 6: Solar Power Basics
3. Solar Power Basics Background Rooftop solar power systems have come a long way, and Westinghouse Solar AC panels break new ground in both performance and safety. Westinghouse Solar AC panels are the first solar panel on the market to integrate racking, wiring, grounding and inverters directly into the panel. This section provides an overview of the installation and operation of your Westinghouse Solar Power System.
Page 7: Using This Guide
5% less than the peak DC output. So at peak conditions, a 235 watt Westinghouse Solar AC panel will produce up to about 223 watts of power. In real world conditions throughout the day, as the sun rises, moves across the sky, and then sets, the output of...
Page 8 The convention we use to describe the orientation of Westinghouse Solar layouts in this guide is that the north/ south direction describes rows of panels that are aligned vertically where north is the peak of the roof, and south refers to the gutter.
Page 9: Section Ii. Westinghouse Solar Ac System Layout And Design
Along with the added efficiencies of Westinghouse Solar AC panels comes a set of unique parameters that need to be considered when laying out your design. Westinghouse Solar’s racking system is built directly into the panel frame.
Page 10: Figure 3 - Six By Two Array Installed In Portrait Mode
Westinghouse Solar AC Installation Guide Figure 3 – Six by two array installed in portrait mode Figure 4 - Comparably sized four by three array in landscape mode Copyright © 2011 - Westinghouse Solar P a g e...
Page 11: Westinghouse Solar Roof Layout Site Surveys
A. Roof type. The most common roof type is composition asphalt shingle. Flat Concrete tile and barrel tile roofs are also compatible with Westinghouse Solar AC panels. This information will determine your specific roofing kit needed. We have included roof attachment profiles that can be included in your plans in the appendix of this guide.
Page 12: Elements Of Designing A Solar System Specific To Westinghouse Solar Ac Panels
Westinghouse Solar AC. You should understand the spacing requirements, mounting methods, and wiring basics that are a part of the Westinghouse Solar AC design. You will need to follow the equipment specific rules below in order to create a safe and efficient Westinghouse Solar AC system.
Page 13: Figure 6 - Roof Top Buffer Room Example On Composition Shingle Roof
Westinghouse Solar AC Installation Guide Unlike with ordinary DC solar panels, the performance of Westinghouse Solar panels will not be compromised by adjacent lower producing panels in the same branch circuit. -Include Buffer Space Around the Array in your Design. Consider the necessary buffer room needed around the array for the roof mount to be sufficiently “flashed.”...
Page 14: Westinghouse Solar Mounting And Structural Requirements
Westinghouse Solar AC Installation Guide 4. Westinghouse Solar Mounting and Structural Requirements To satisfy Westinghouse Solar's minimal structural requirements there are two simple design rules that usually dictate the minimum mounting requirements. As Westinghouse Solar AC panels are connected together they form a rigid structure. The span of the panels between roof attachments is generally 48”.
Page 15: Figure 9 - Profile Of Roof Attachments With Shared Center Attachment Point Across Two Panel Rows
When designing a multiple row array with Westinghouse Solar AC, the entire array can be seen as a unified structure, and not single rows of panels on independent racking systems as with ordinary solar panels.
Page 16: Drafting A Solar Array
Adding Additional Equipment to the Roof Layout Westinghouse Solar AC Wire Runs After the roof layout is complete with Westinghouse Solar AC panel locations and the existing electrical service, identify where conduit or Romex will be run to route the arrays conductors to the associated equipment on the ground.
Page 18: Section Iii. Creating An Electrical Diagram
1. Westinghouse Solar AC Electrical Requirements A. Westinghouse Solar AC Panels may be arranged in branch circuits of up to 15 when working with 240V single phase electrical systems. Each branch circuit will need to be isolated using NEC compliant circuit protection B.
Page 19: Single Line Diagram Preparation
E. Wiring Location- Is there a clear pathway through crawl spaces and attics to route your Westinghouse Solar AC system conductors? Will the wire run be external to the structure? How long is the wire run? This information will be a factor in sizing your Copyright ©...
Page 20: Electrical Line Diagram
Westinghouse Solar panels. Westinghouse Solar splices are a UL listed grounding component. At the end of each row in the east-west orientation there is a factory designated bonding location for attaching a lug.
Page 21: Figure 12 - Single Branch Circuit Westinghouse Solar Ac Wire Diagram
Westinghouse Solar AC Installation Guide Figure 12 - Single Branch Circuit Westinghouse Solar AC Wire Diagram Copyright © 2011 - Westinghouse Solar 17 | P a g e...
Page 22: Section Iv. Installation
16" of the closest rafter to the interior of the array. Westinghouse Solar AC modules may not overhang the last array attachment point by more than 16" or 40% of the module’s width. Remember to include 7/8" of space between modules in the north-south direction.
Page 23: Figure 13 - Laying Out Attachment Points For Westinghouse Solar Modules
In the following sample array there are three rows of attachment points to accommodate two rows of Westinghouse Solar modules. The first row of attachment points starts at the bottom horizontal perimeter of the Array.
Page 24: Figure 14 - Tapping Across Assumed Rafter Location To Find Firmest Point
By bending back the course of shingles where you are penetrating, you will be able to easily seal and cover any misses. Figure 14 - Tapping across assumed rafter location to find firmest point Copyright © 2011 - Westinghouse Solar 20 | P a g e...
Page 25: Mounting
Westinghouse Solar AC Installation Guide 3. Mounting The examples that follow illustrate how to install Westinghouse Solar Power Systems mounting components on composition a shingle roof. Step 1A. Pre-drill at the pre-determined roof penetration chalk markings established in step 2 of this section.
Page 26 This 1/8" of space will allow the installer to line up and adjust the L brackets before tightening them down to their final position. Excess caulk should squeeze out of the hole and surround the head of the lag bolt. Copyright © 2011 - Westinghouse Solar 22 | P a g e...
Page 27: Module Installation
This marking identifies a left hand thread at that end of the splice. Use this marking to quickly identify which end of the Westinghouse Solar splice you are holding. Splice Channels are either marked with three small circles to identify a left hand thread fit or are blank to identify a right hand thread pattern.
Page 28: Figure 17 - Westinghouse Solar Splice Thread Direction
(Tightening Westinghouse Solar Splice and frame left hand thread marking pattern Westinghouse Solar Module Torque Specifications Westinghouse Solar Splices require 5-7 ft/ lbs of torque to fully engage in the east/ west direction. As an approximation, once you feel the Westinghouse Solar splice fully seated, turn the Westinghouse Solar wrench 1/8 of a turn, this will create the appropriate amount of torque for the connection of modules in the east/ west direction.
Page 29 Westinghouse Solar AC Installation Guide Step 1 - Westinghouse Solar module lowered on to L bracket using 3/8" hex bolts as a resting point. Repeat this step at both the upper and lower short edges of the module. Step 2 - Loosely thread 3/8" Flange nut onto Hex bolt, prepare for second module by inserting upper and lower Westinghouse Solar Splices.
Page 30: Connecting Westinghouse Solar Ac Wiring Harnesses
Westinghouse Solar AC Installation Guide Step 4 - Rotate Westinghouse Solar splices within the frame to draw two modules together. This can be done using the V2 wrench or with the V2 hex splice driver and a 1/4" drive ratchet. Green arrows indicate splice rotation.
Page 31: Figure 18 - Single Row Of Westinghouse Solar Modules Installed
Extension Cable that will reach the upper row modules bulkhead connection. Westinghouse Solar AC Extension Cables are available in a length of 6', 12' and 20'. Tip: Careful planning of wiring layouts will create a quick installation without interruptions or the need to purchase additional equipment.
Page 32 Tip: If a module is left out of the array to make room for a roof vent, an additional North /South bracket may be required to support the second row and maintain Westinghouse Solar structural requirements.
Page 33: Grounding
Groove into the open end of the North/ South Bracket. Secure this hardware with the V2 Westinghouse Solar wrench once the outer edges of the two rows are flush. By tightening this hardware in this step you will avoid the module sliding out of alignment when the next module is spliced in the east/ west direction.
Page 34: Adding Ac Interconnect Parts
AC interconnection cable is in proximity to the junction box. The junction box is the location where conductors from the array transition to conductors that will run down to the main Copyright © 2011 - Westinghouse Solar 30 |...
Page 35: Commissioning Westinghouse Solar Ac Systems
Westinghouse Solar AC Panel to Junction Box wiring – On the end of a row of panels, attach a grounding lug to the frame at one of the designated grounding attachment points of one panel using the thread forming grounding screw.
Page 36 Please verify proper AC cable voltage and neutral conductors prior to connecting to live voltage or connecting the harness to the Westinghouse Solar AC string. Failure to properly connecting the wires can result in severe damage and void the warranty.
Page 37: Section V. Westinghouse Solar Operations
Other Faults: All other faults are reported to the EMU. Refer to the EMU Installation and Operation Manual for a list of additional faults and troubleshooting procedures. Copyright © 2011 - Westinghouse Solar 33 | P a g e...
Page 38: Troubleshooting An Inoperable Inverter (For Experienced Installers)
5. Check the DC connections between the inverter and the PV panel. 6. If the problem persists, please call customer support at Westinghouse Solar. 3. Disconnecting the Inverter from the PV Panel To ensure the inverter is not disconnected from the PV panels under load, adhere to the following disconnection steps in the order shown: 1.
Page 39: Section Vi. Definitions
North-South Bracket - The North-South Bracket serves as a structural connection for V2 60 Cell Westinghouse Solar Power Systems and enables sharing of footings between the first and second rows (and all consecutive rows until the top of array).
Page 49 Step 3. Apply roofing sealant to roof Step 4. Install Lag Bolts and washers to secure penetration area. bracket in place. Step 5. Replace previously removed tile at attachment location. Copyright © 2011 - Westinghouse Solar P a g e...
Page 50 Step 3. Apply sealant to attachment location. Step 4. Place standoff base over pre-drilled hole. Step 5. Using lag Bolt with included washer, attach standoff base to roof surface using an impact driver. Copyright © 2011 - Westinghouse Solar xi | P a g e...
Page 51 Step 6. Mold Flashing material to the profile of existing tiles. Install aluminum standoff into base once flashing is in place. Step 7. Seal flashing with vinyl roofing tape and loosely assemble assocated attachment hardware. Copyright © 2011 - Westinghouse Solar xii | P a g e...
Page 52: Section Viii. Technical Support
Westinghouse Solar AC Installation Guide Section VIII. Technical Support The following contact options are available for support of questions regarding product, installation, operation or warranty of your Westinghouse Solar AC system: Phone: 1.888.395.2248 (option 2) Email: tech@westinghousesolar.com Fax: Westinghouse Solar Tech Support - (408) 395-7979...
Page 53: Table Of Figures
Figure 10 - Westinghouse Solar inter-panel spacing and panel dimensions ..........12 Figure 11 - Inverter components in a two row array .................. 15 Figure 12 - Single Branch Circuit Westinghouse Solar AC Wire Diagram ........... 17 Figure 13 – Laying out attachment points for Westinghouse Solar Modules ..........19 Figure 14 - Tapping across assumed rafter location to find firmest point ..........

Westinghouse AC System Installation Manual

Table of Contents

Section I. Getting Started

Section II. Westinghouse Solar AC System Layout and Design

Section III. Creating an Electrical Diagram

Section IV. Installation

Section V. Westinghouse Solar Operations

Section VI. Definitions

Section VII. Appendix

Section VIII. Technical Support

Table of Figures

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Summary of Contents for Westinghouse AC System

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