solarbuildermag.com march/april 2014 behind the scenes at ... · dan sisko [email protected]...

solarbuildermag.com March/april 2014

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B at t e ry Using google glass

Rooftop safety

solaR Jobs CensUs

Also InsIde:

solarbuildermag.com | 3

cover storyInsIde Crown BatteryCrown Battery Manufacturing Co. invited Solar Builder for a behind-the-scenes tour of its headquarters in Ohio. Take a look at how batteries are made and how the company differs itself from other renewable manufacturers.

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departmentsmountIng and raCkIng

no Clamps? no proBlem. Creotecc’s clamp-free mounting system designs can be installed quickly and are better for the overall life of the system, especially the modules.

BalanCe of system

seCurIty system HitchClip, a new rooftop safety product, promises to make solar installers work faster and safer while also having convenient accessory attachments ideal for active installers.

18

☼ on the coverThe many various steps in the renewable battery manufacturing process are shown, all from inside Crown Battery Manufacturing Co.’s head-quarters in Fremont, Ohio.

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contents March/april 2014

4 march/april 2014

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contents March/april 2014

32

Delaware takes a green stanDNot making any progress on the state’s Renewable Portfolio Standard, the Delaware Electric Co-op installs a 4-MW solar field and gets the ball rolling.

32

Featureswhat can google glass Do for you? The futuristic glasses could become a present day aid to solar installers sooner than we think. Sullivan Solar Power has already developed apps to take advantage of the device.

36 Built-in solar power A new snap-on BIPV product hopes to take the new build and re-roofing market by storm. The SolTrak tile is already making waves in Western Canada and has plans for the United States.

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Atkore ........................................................... www.atc-mechanical.com ............................... 7

crown Battery ............................................... www.crownbattery.com ................................. 44

Fronius llc usA .......................................... www.fronius-usa.com .................................. 11

intersolar north America ............................... www.intersolar.us ........................................ 16

intersolar summit ......................................... www.intersolarglobal.com ............................ 43

Pv America ................................................... www.pvamericaexpo.com ............................. 12

quickscrews international .............................. www.quickscrews.com ................................... 5

roof-tech ..................................................... www.roof-tech.us ........................................... 2

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key industry abbreviations

PV: photovoltaics (using solar cells to produce electricity)

V: volts

W: watt

kW: kilowatt or 1,000 W

MW: megawatt or 1,000 kW

GW: gigawatt or 1,000 MW

kWh: kilowatt hour

BOS: balance of system (all components except PV panels)

6 march/april 2014

editor’s message

23,682 new solaR bUildeRsAccording to The Solar Foundation’s fourth annual National Solar Jobs Census, the

U.S. solar industry increased employment in 2013 by 19.9 percent over 2012. An addi-tional 23,682 jobs were filled across the country, and solar employers expect to add another 22,000 in 2014. By comparison, the fossil fuel electric generation sector shrank by more than 8,500 jobs in 2013, and jobs in coal mining grew by just 0.25 percent.

Solar has a lot of room to grow, and we’re obviously taking advantage. You can see our census map on Page 28 to see how your state fared in the past year. Every state saw an increase in workers, with the exception of a few, including hefty losses in Arizona and Pennsylvania. Even with a 1,200 loss, Arizona still ranks second in the country by total number of solar jobs at 8,500. It’s a long climb to the No. 1 spot, held by California with more than 47,000 total solar workers. California employs one third of all U.S. solar workers, and the Golden State doesn’t show signs of slowing down.

The Solar Foundation found that solar companies reported that cost savings were driving their clients’ decision making, as 51.4 percent of customers report turning to solar to save money, and another 22.9 percent are installing solar because costs are now competitive with utility rates. Strong policy changes in states like Massachusetts and Georgia will only further to make solar attractive to consumers.

Looking forward to a busy summer,

Kelly Pickerel, Associate Editor

solar Builder (issn 2166-5362) is published bimonthly by Benjamin Media inc., 10050 Brecksville rd., Brecksville, oh 44141 usa. copyright 2014. all rights reserved. no part of this publication may be reproduced without written permission from the publisher. one year subscription rates: complimentary in the united states and canada. single copy rate: $10. subscriptions and classified advertising should be addressed to the Brecksville office. postmaster: send address changes to solar Builder, 10050 Brecksville road, Brecksville, oh 44141 usaCanadIan suBsCrIptIons: canada post agreement number 7178957. send address change information and blocks of undeliverable copies to canada express; 7686 kimble st., units 21 & 22, Mississauga, on l5s 1e9 canada.

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8 march/april 2014

news

The Energy Department an-nounced in February that the U.S. solar industry is more than 60 percent of the way to achieving cost-competitive, utility-scale solar PV electricity — only three years into the Department’s decade-long SunShot Initiative. To help continue this progress, the Energy

Department also announced $25 million in funding to strengthen U.S. solar manufacturing for PV and concentrating solar power (CSP) technologies and to main-tain a strong domestic solar indus-try — supporting the Department’s broader Clean Energy Manufactur-ing Initiative.

In the State of the Union ad-dress, President Obama high-lighted the United States’ grow-ing role as a global leader in solar as demonstrated in a new industry report which recently found that U.S. utility-scale solar set a record with 2.3 GW installed in 2013.

U.S. Utility-Scale Solar

60% Toward coSt-competition Goal

“In just the last few years, the U.S. has seen remarkable increases in clean and renewable energy — doubling the amount of energy that we produce from solar and wind and supporting a strong, competitive solar supply chain that employs American workers in every state,” said Energy Secretary Ernest Moniz. “To continue this growth and position the U.S. as a global leader in clean energy in-novation, the Energy Department is helping to advance new tech-nologies that further reduce costs, improve performance and support new jobs and businesses across the country.”

In 2011, the Energy Department launched its SunShot Initiative to make solar energy cost-competitive with traditional energy sources by the end of the decade. Through partnerships with the solar indus-try, universities, local communities and the Department’s national laboratories, the SunShot Initiative is working aggressively to drive in-novation and lower the cost of so-lar energy — from more efficient, high-performing solar modules to streamlined permitting, installation and interconnection processes.

Today, the utility-scale PV industry is more than 60 per-cent of the way to achieving SunShot’s target of $0.06 per kilowatt-hour. In the United States, the average price for a utility-scale PV project has dropped from about $0.21 per kilowatt-hour in 2010 to $0.11 per kilowatt-hour at the end of 2013. According to the Energy Information Administration, the average U.S. electricity price is about $0.12 per kilowatt-hour.

Reductions in the cost of electricity are based on esti-mates of the levelized cost of electricity (LCOE). The LCOE

is a measure of the national aver-age of electricity cost based on certain assumptions regarding financing costs and generation availability projected over the life of a generating asset. The LCOE model provides a benchmark for measuring relative changes in elec-tricity costs.

During President Obama’s first term, the United States more than doubled generation of electricity from wind, solar and geothermal sources, and installed solar capacity has grown ten-fold from 1.2 GW in 2008 to an estimated 13 GW today. To ensure America’s continued lead-ership position in clean energy, the President has set a goal to double renewable electricity generation once again by 2020.

$25 million To BoosT U.s. solar manUfacTUring

Over the last three years, the cost of a solar energy system has dropped by more than 50 percent, helping to give more and more American families and busi-nesses access to affordable, clean energy. The Energy Department

announced $25 million in new funding to boost domestic solar manufacturing and speed up the commercialization of efficient, affordable PV and CSP technolo-gies. This funding opportunity will help to further lower the cost of solar electricity, support a growing U.S. solar workforce and increase U.S. competitiveness in the global clean energy market.

This new SunShot funding op-portunity will support innovative projects that help solar manufac-turers tackle key cost-contributors across the hardware supply chain and make improvements in a broad range of manufacturing processes that save time and mon-ey. Eligible projects may include developing advanced technology that lowers domestic solar manu-facturing costs and developing and demonstrating components or new manufacturing processes that cut project construction and installation time.

The Energy Department’s SunShot Initiative aims to make solar energy fully cost-competitive with traditional sources of energy by 2020.

solarBUildermag.com | 9

10 march/april 2014

news

trackinG manUfactUrer offerinG free welder traininG proGram

ERCAM Trackers, a Texas solar tracking manufacturer, is hosting free welder training programs to fill positions in San Antonio’s renew-able energy industry. Participants will have the opportunity to join ERCAM as a full-time employee with benefits upon completion of the training.

ERCAM’s first free welder train-ing wrapped up in January with 90 percent of the students moving into permanent, full-time positions in the U.S. solar manufacturing indus-try. Another session will take place in Q1 2014.

ERCAM supplies mounting systems that track the sun for OCI Solar Power’s 400-MW solar deal with CPS Energy that pairs both sizeable generation with economic development. The 400-MW project resulted in the largest economic development agreement between a municipal utility and private company. The partnership will bring manufacturing, 800 permanent jobs and an annual economic impact of $700 million to Texas.

ERCAM is looking for indi-viduals with basic machine skills to complete the 80-hour training

program led by a master welder. The program is free to partici-pants. The program covers safety, equipment use and care and on-the-job training.

Upon successful completion of the course, which includes passing an exam evaluated by a master welder, participants will have the opportunity to join ERCAM as a full-time employee with benefits and paid vacation.

Please contact ERCAM Trackers at 210-807-9880 to inquire about training and career opportunities.

solarBUildermag.com | 11

Duke Energy has issued a request for proposals (RFP) for 300 MW of new solar energy capacity in its Duke Energy Carolinas and Duke Energy Progress territories. The new capac-ity would be in service by the end of 2015.

The RFP gives bidders the flex-ibility to offer power and associated renewable energy certificates and/or to provide a turnkey solution in which Duke Energy takes ownership of the new facility.

The RFP allows Duke Energy to further its commitment to renew-able energy, diversify its energy mix and meet North Carolina’s Renew-able Energy and Energy Efficiency Portfolio Standards (REPS).

“This proposal will practically double our current solar capacity for

customers in the Carolinas,” said Rob Caldwell, vice president of renewable generation development. “It gives developers the opportunity to pursue projects for the long term or to negotiate for Duke Energy to acquire ownership of the new facilities once they are operational.”

The company’s RFP is targeting solar facilities greater than 5 MW. It is limited to projects that are in the company’s current transmission and distribution queue, as those have a realistic chance to be completed by the end of 2015. Duke Energy affili-ates will not be allowed to participate in the RFP.

Caldwell added there are many eligible projects — with more than 2,500 MW of capacity being pro-posed in the state by solar developers.

“Our mission is to bring more renewable generation onto the Duke Energy system in the most cost-effective manner possible,” said Caldwell. “This RFP allows the com-pany to take advantage of projects already in the planning stages.”

Caldwell said the company should be able to have projects selected and negotiations completed by Oct. 1, 2014. North Carolina’s REPS allows for renewable energy facilities con-nected to the Carolinas system to meet the state’s compliance obligations. As a result, facilities in South Carolina will be eligible to submit proposals for the power and associated renewable energy certificates, if they meet other criteria in the RFP. More information about the Carolinas RFP can be found at duke-energy.com.

DUke enerGy iSSUeS rfp for 300 mw of new Solar projectS in nc

12 march/april 2014

news

Meach Cove Farms and groSolar have announced the completion of Limerick Road Solar LLC, a 2.96-MWdc solar PV system in Shel-burne, Vt. Project design and solar engineering was performed under the direction of L.W. Seddon LLC and the installation and construc-tion was managed by groSolar. The project is located on 15 acres of the 1,000-acre Meach Cove Farms, a certified organic farm focusing on efficiently using local natural resources.

“The Limerick Road Solar proj-ect enhances the mission of Meach Cove Farms and will provide many benefits to our surrounding commu-nity. As an organization, we conduct research on projects which provide

renewable energy alternatives to fos-sil fuels. This solar project represents an important step forward in reduc-ing our dependence on fossil fuels and creating clean, renewable energy for the community,” said Christo-pher W. Davis, manager of Meach Cove Farms.

Average annual electrical produc-tion from the facility is estimated to be 3,450,000 kilowatt hours (kWh), which is equivalent to the annual electrical consumption of 385 aver-age Vermont homes. The electricity produced will be sold to Vermont utilities under the state’s Sustain-ably Priced Energy and Economic Development (SPEED) program. The solar facility uses 9,878 Rene-sola 300-W PV modules mounted

on a Schletter racking system. DC power is converted into utility-grade AC power by five Advanced Energy inverters located in two PowerSta-tion enclosures.

“Working with groSolar and Meach Cove Farms on this project has been a very successful collabora-tion. All three of our organizations are dedicated to designing and con-structing renewable energy solutions that utilize local resources in the most environmentally responsible and cost-effective way,” stated Leigh Seddon, of L.W. Seddon LLC. “This project was completed on sched-ule and within budget due to the excellent project management and collaboration between groSolar and Meach Cove Farms.”

GroSolar inStallS 2.96-mw projecT

for Vermont orGanic farm

GroSolar inStallS 2.96-mw projecT

for Vermont orGanic farm

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14 march/april 2014

No Clamps?pRoBlEm.

mounting

Clamping and mounting are two terms usually linked together in the solar industry. It’s diffi-cult to even do a simple Internet search for clamp-free mounting systems, but let it be

known — they are out there. Creotecc Solar Mounting Systems, located outside of San Jose, Calif., manufac-tures both roof- and ground-mount systems requiring no clamps to secure modules. The company says clamping is bad for panel-longevity and slows down installation. Modules “float” between rails in a Creotecc system, and they can be secured much quicker than traditional sys-tems allow. Once more people under-stand the benefits of going clamp-less, Creotecc believes the solar industry will see more successful projects.

EasY oN THE moDUlEsCreotecc Solar Mounting Systems

was founded in Germany in 1999 and entered the U.S. market eight years later. Originally a subsidiary of U.S. solar distributor Session Solar, the Creotecc mounting systems became the main focus of the com-

pany and the wholesale division was dropped in 2012. Now a subsidiary of BayWa r.e. Renewable Energy, an international holding company for businesses interested in renewable energy based in Germany, Creotecc takes advantage of BayWa’s experi-ence and understanding of the solar industry to grow more aggressively in the United States.

After much research, Creotecc stands behind its claim that clamps do more harm than good. Using basic thermal imaging, you can see the pressure clamps put on modules, which can lead to reduced output and failure, says Cale Garamendi, Creotecc sales manager. The compa-ny’s CREOTERRA ground-mount and CREOMOUNT roof-mount systems take clamps completely out of the picture. Instead, the systems use channeled, horizontal insertion rails to secure panels into an array. Modules are slipped into the top rail and then dropped down into the bottom. The panels sit between the rails, and edge-stops secure the arrays in place.

“What we’ve come to realize [is that] this technique is much easier on the modules in general,” Garamendi says. “In no case are these installers climbing up on top

of the array to fasten any sort of clamp. You avoid damage to the modules by installing from below with very little pressure on the mod-ules. They’re allowed to float freely in those rails and provide very little resistance as there’s room for ther-mal expansion and contraction.”

Garamendi says indirect damage to modules has become more of an issue in the industry because many module manufacturers write their warranties so that any damage done during installation won’t be covered. When installers climb on top of an array, a knee or elbow into a panel could leave microfractures not notice-able to the naked eye, but thermal imaging shows very clearly the dam-age done. Clamping modules restricts thermal expansion and has the same fracturing effect.

“From an O&M standpoint, [the Creotecc mounting system] really helps protect the warranty for the modules and helps to ensure the production that is guaranteed by the manufacturers,” Garamendi says. “Installers can carelessly drop a module, and that could happen regardless of the mounting system type. But assuming that they get the module into place without dropping it prior to the mounting


Clamps? CREoTECC solaR moUNTiNg sYsTEms pRoDUCEs Clamp-fREE DEsigNs

THaT CaN BE iNsTallED qUiCklY aND aRE BETTER foR moDUlEs.

By Kelly Pickerel

16 march/april 2014

of the module, Creotecc’s installation process is painless for the solar panel.”

laBoR REDUCEDThe convenient drop-in fea-

ture of Creotecc mounting sys-tems also limits the hard labor installers have to do. No longer does extra time have to be spent screwing, fastening or clamping modules into an array.

Elite Solar in Chico, Calif., has been using the CREOTERRA ground-mount system on projects ranging from farms, municipalities and school districts. Jamie Sanchez, vice president of business development, says Creotecc first approached Elite to try out the new product back in 2012. Elite had been working with Session Solar and its wholesale division, and when Creotecc intro-duced its clamp-free system design, Sanchez says Elite didn’t think twice about trying the new product.

“We had great respect and trust for the management and sales team (of Creotecc),” he says. “After a couple demonstrations, we knew this was a great product and a great fit for Elite Solar.”

Prior to installing Creotecc mounting systems, Elite Solar has used its own custom-made racking design that used clamps and fasten-ers to secure modules. The compa-ny’s first project with the Creotecc system was a 500-kW ground-mount in California.

“Once changing from our origi-nal application to using Creotecc, it cut the install time by 38 percent,” Sanchez says. “Creotecc’s special-designed insertion rail allows our crews to install and secure modules in just minutes.”

lEss CosTCreotecc’s roof-mount system is

just as easy to install as on the ground. The CREOMOUNT is ideal for long spaces with room for multiple rows. Having the ability to share multiple rails cuts down on costs.

Freedom Solar, an installer based in Campbell, Calif., switched to Creotecc mounting systems three years ago. Bryan Whitton, Freedom Solar owner, had been using a popu-lar mounting company’s clamped system on residential roof installs when he decided enough was enough and sought out Creotecc.

“I don’t like hard-mounting modules,” Whitton says. “They’re glass, and I don’t like them being hard-mounted. I’ve always thought that was a silly solution. Creotecc uses a shared rail that allows the modules to float rather than being firmly attached. Because there’s a shared rail, there is typically 25

percent fewer penetrations on the roof. With fewer penetrations, there is less likelihood of leaks. The installation process is significantly lower. It looks better, performs bet-ter, is less expensive. When you look at the pros and cons, there’s just no comparison.”

Whitton says the Creotecc system works extremely well on awkwardly-designed roofs.

“We have found it to be incredibly flexible,” he says. “Whether you’re going in portrait or landscape mode, you can intermix them very easily and very cost-effectively, and it still looks greats too. That’s something people overlook. Sometimes you have to have a combination of land-scape and portrait, and that’s a piece of cake with Creotecc.”

Kelly Pickerel is editor of Solar Builder.

@solar_builder

solarbuildermag.com

mounting

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18 march/april 2014

bos

Security SyStem

the Hitchclip provides a level of protection to installers working on sloped roofs. By Kelly Pickerel

The solar industry is drowning in choic-es for mounting, inverting, combin-ing and more. But one thing the

industry is thirsty for is safety equipment and fall arrest systems, especially for residential rooftop installs. The HitchClip, manufac-tured not specifically for solar but for the roofing industry, provides contractors with a useful alterna-tive to bulky, awkward safety equipment. Instead of being bur-densome, the HitchClip inte-grates rooftop safety with produc-tion, and all solar rooftop install-ers should take notice.

Scott Fontaine, a founder of SAFE Acquisition LLC, the force behind the HitchClip product (and recently acquired by Guardian Fall Protection), was a general contractor for 30 years before branching out with safety equipment manufacturing. He knows first-hand the issues with safety and production up on the roof.

“The biggest problem across the nation is guys just don’t use it,” he says of safety equipment. “They’re starting to buy it and they have it scattered around on the roof so it appears that they’re using it when OSHA shows up. They’re hoping to not get fined.”

Mike Vasquez, product consul-tant and research and develop-ment with SAFE, says that the OSHA guidelines vary across dif-ferent states, but the main rule is that if you’re above 6 ft (whether on scaffolding, a roof, a ladder or anything), you need to be tied off. Many contractors don’t understand the consequences of a fall.

“Guys just really aren’t aware of what the ramifications are from taking a fall and how to prevent

those things,” Vasquez says. “They just want to get the job done, and they think that anything with fall arrests — their lifelines, their har-nesses — takes time to set up to stay in compliance.”

Fontaine says the main issue is that most safety equipment is cumbersome.

“When you have equipment that slows you down when you work, you lose money and go out of business,” he says. “Contractors are a pretty surly group. They’re not going to do what they don’t want to do, and they’re certainly not going to do what slows them down and costs them money.”

So Fontaine started focusing on marrying safety with production. He began coming up with sys-tems and playing with them at his jobsites to see what worked and what didn’t.

“As a builder, every day I had to fix problems and figure things out and jerry-rig stuff to get through the day,” he says. “I put it into research and development where I actually built equipment to do the job and I was able to field test it every day until I got it just right. I made it so that it actually made you work faster not slower, having that safety factor in there as well to appease OSHA.”

The HitchClip was born. Made of light-weight aluminum, it functions as a permanent rooftop anchor. The top of the product fastens to the roof, while the bot-tom has a patented key-hole design, which allows users to attach safety equipment and other SAFE accessories directly to the anchor. The HitchClip comes in three colors — grey, black and brown — and blends in with sur-

rounding shingles and tiles. SAFE expects big things for

2014. Now in its fourth year of existence, the company has a partner in Guardian Fall Protection, a manufacturer and provider of fall protection solu-tions. Guardian holds a world-wide license on the distribution of HitchClip and its accessories. SAFE’s partnership with Guardian has opened up many new distribution channels, allowing the company to focus more on R&D.

In addition to the HitchClip, Guardian sells the SAFE-designed Roof Jack (a staging area), Bunk Jack (an oversized Roof Jack for larger materials), Platform Stage (creating a lad-der and staging system in tight


Security SyStem

ADD ONS AND EXTRAS The HitchClip allows for attachment of SAFE accesso-ries, like the Roof Jack staging area, seen here.

20 march/april 2014

spaces), Workbench (a por-table rooftop work area to perform cuts or tooling), Guardrail (a guardrail that attaches to the Roof Jack) and now the Solar Mount, a mounting system that uses the HitchClip. The HitchClip acts as a base, and the Solar Mount clicks right into it. Panels can be mounted in both portrait and landscape arrangements. Installers can combine SAFE’s fall protection, pro-duction staging and solar mounting now into one sys-tem.

“The HitchClip is an anchor for your fall arrest system, but the keyhole design also accepts all of our line of production equipment that quick connects into the keyhole,” Fontaine says. “Not only are you tied off, you have a whole series of staging equipment and guardrails and other safety items that basi-cally make it a complete system.”

Encouraging the effective use of safety anchors was one goal for SAFE, but then providing even easier ways to get the job done was an added bonus.

“All anchors that are on the market right now, that’s all they are — just a hook-up point,” Fontaine says. “We built off of it. We made it low-profile, and it comes in different colors so it blends seamlessly into the roof. It gives them so much more.”

HitchClip is designed to be a permanent fixture on a roof, but Fontaine says every contractor is going to choose a different way to

use it. They can be temporary and moved around, but once contrac-tors get used to using them, they’ll find that leaving them in one spot works the best. Since the HitchClip comes in roof-neutral colors, they’re not an eyesore, and contractors can easily have a whole array of work zones on the roof without anyone being able to tell down below. Permanently securing HitchClips to a roof makes it easi-er for future maintenance, too.

“Anywhere there’s a rafter next to you, you can screw it on and have an anchor point within a few feet of you,” Fontaine says.

After 30 years up on roofs, Fontaine jokes that he doesn’t mind not having to climb up there every day and work in the rain. He’s found a new, rewarding career helping contractors stay safe and still be productive.

“It’s rewarding to use my knowl-edge now to help guys out,” he

says. “At shows, it’s so much fun showing off the product to guys who haven’t seen it before because you can just see the light bulb go off. It’s one of those ‘Why didn’t I think of that?’ products.”

Vasquez agrees that his 23 years as a roofer and framer help him produce better products for those on the job.

“We develop products that we’ve talked to contractors out there that need a solution for some-thing, and we come up with it,” he says. “We know how to imple-ment it into a project as opposed to an engineer. Anyone can draw up a design, but to actually imple-ment it into the field is where we separate ourselves from the rest of the pack.”


bosFALL SECURITY

Keeping roofers safe and secure on roofs is the main

purpose of the HitchClip.

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B AT T E RY USING GOOGLE GLASS

ROOFTOP SAFETY

SOLAR JOBS CENSUS

ALSO INSIDE:

22 march/april 2014

On a frigid day last year during the holiday sea-son, Crown

Battery Manufacturing Co. invited Solar Builder for a factory tour at its headquar-ters in Fremont, Ohio. We were able to see how the company makes its batteries — for applications ranging from automotive, marine, mining and renewable ener-gy — and witness its push to be more green. Not only has the company hopped into the renewable energy indus-try, it has also installed solar panels, geothermal systems and wind turbines at its assembly plant. Crown also prides itself on its recycling programs and new air-han-

dling system to improve work conditions at the 400-employee factory.

Crown Battery has been in business for almost 90 years and in the last decade or so invested millions into manufacturing and R&D to make advanced technology batteries. Seeing a demand for renewable energy batter-ies, Crown built a new lead-acid battery from the ground-up. Understanding that renewable energy applications experienced harsher conditions than environments running the tried-and-true automotive battery, Crown redesigned its grids and active lead materials so batteries would last longer.

Solar Builder’s behind-the-scenes tour, expertly given by Aaron Opelt, regional sales manager, gave us an up-close look at how renewable energy batteries are made. All of the compa-ny’s batteries are manufac-tured in the same place using the same processes, so we got to see how many types make their way down the line. Take a look at how an important product in many residential solar installations is built, from start to finish.


@solar_builder

solarbuildermag.com

cover story

Behind the SceneS at crown Battery


Behind the SceneS at crown Battery

The lead is heated to a molten state and then converted to a powdered oxide form that looks like cinnamon. At Crown, lead is processed into lead oxide 24 hours a day. The only time the oxide mill shuts down is for spring cleaning. Quality checks of lead oxide are done every half hour.

Crown Battery uses recycled lead in its batteries. Different types of lead are used for differ-ent batteries. Its renewable energy batteries use antimony-alloyed lead for battery grids and primary lead for finished plates.

STEP 2

STEP 1 H o w B AT T e r I e s A r e M A D e

24 march/april 2014

Active lead material made from lead oxide is pressed onto the grids. There are different active lead or “paste” mixtures for the positive and negative plates. once the paste is applied to the grid, it goes through a flash oven. At Crown, a special camera records an image to make sure the grids are completely covered with paste. If it is not covered, the line will shut down. The pasted plates go into specialized drying ovens for eight to 84 hours to take out additional moisture. Not com-mon at all battery manufacturers, Crown has 26 ovens in the plant to speed up drying and prolong the plate’s useful life.

STEP 4

Grids are gravity cast. They’re extremely flexible yet very durable.

STEP 3


A plastic heatseal process connects and seals the battery’s cover and con-tainer. Then batteries are filled with air and marked with a special production code consisting of the date, line number, battery type and time of manufac-ture to ensure transparent traceability of batteries once they leave the factory.

STEP 5

STEP 6

Positive plates are wrapped in a fiber-glass and micro-porous polyethylene material and completely sealed along the plates’ bottom horizontal and two vertical edges. Positive plates are then stacked on top of negative plates. These grids are

placed in the battery case by a robot. A robotic cast-on-strap (Cos) machine then makes a top weld, join-ing all lugs into a series of connections. electrical currents are run through the assembled product to make sure everything is connected correctly.

26 march/april 2014

Battery charge levels are monitored during the formation process, and at the completion of charging, Crown’s Quality Control verifies product integ-rity before releasing products for final packaging. Batteries get hot when

charging, so Crown uti-lizes an acid recirculation system (Ars) system that pumps in cooled electrolytes through bat-tery cells to enable bat-teries to charge more efficiently.

The battery is filled with electrolytes, connected to wires and then sent to a formation charging process.

STEP 7

STEP 8


*Although many different batteries are shown, Crown’s renewable energy batteries are manufactured in a similar process.

Crown’s final inspection and packaging processes cleans and dries batteries and applies a series of final electrical capacity inspections to validate product integrity. Finally, safety and brand labels are applied to batteries before final shipment to the company’s corporate and independent distribution community.

STEP 9

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28 march/april 2014

feature

State 2013 solar jobs

2013 job ranking

Change in jobs since 2012

total solar companies

# of homes powered by solar

Top employment

sector

Alaska 50 51 -50* 13 <150 Installation

Arizona 8,558 2 -1,242 288 180,091 Installation

Arkansas 400 43 +270* 13 <150 Installation

California 47,223 1 +3,523 1,672 898,548 Installation

Colorado 3,600 9 0 328 56,694 Installation

Connecticut 1,100 28 +420 108 5,615 Installation

Delaware 510 41 +150* 41 5,326 Installation

Florida 4,000 7 +1,500 309 20,299 Installation

Georgia 2,600 16 +1,800 146 3,255 Manufacturing

Hawaii 2,600 16 +1,000 88 57,689 Installation

Idaho 540 38 +240* 33 <150 Manufacturing

Illinois 2,100 19 +400 189 6,241 Manufacturing

Indiana 1,500 25 +960 50 421 Manufacturing

Iowa 680 35 +470* 34 <150 Installation

Kansas 530 40 +250* 21 <150 Manufacturing

Kentucky 640 36 +170* 37 410 Manufacturing

Louisiana 1,400 26 +960 43 1,437 Installation

Maine 790 34 +520* 40 553 Installation

The Solar Foundation’s annual National Solar Jobs Census was released early this year, and the results have been eye-opening.

The U.S. solar industry employed 142,698 Americans in 2013, an increase of 23,682 jobs over 2012, or a 19.9 percent growth. Solar employment grew 10 times faster than the national average employment growth rate of 1.9 percent in the

same period. Every state saw growth, with the exception of Alaska, Arizona, Oregon and Pennsylvania, which saw losses, and Colorado and Nevada which saw no change. What you’ll see on the next few pages is a snippet of some of the exciting facts. Below you’ll see how each state stacks up. A full list of information and an interac-tive map can be found at solarstates.org.

2013 solar jobs census



* Job figures for the 20 states with the least amount of installed solar capacity may suffer from larger margins of error due to a lack of in-state data.

State 2013 solar jobs

2013 job ranking

Change in jobs since 2012

total solar companies

# of homes powered by solar

Top employment

sector

Maryland 2,000 20 +100 132 12,916 Installation

Massachusetts 6,400 4 +1,900 283 51,618 Installation

Michigan 2,700 14 -300 176 2,775 Manufacturing

Minnesota 864 31 +364* 90 1,672 Installation

Mississippi 240 49 +20* 10 <150 Manufacturing

Missouri 2,800 12 +1,600 70 2,664 Manufacturing

Montana 540 38 +440* 29 267 Installation

Nebraska 280 48 +160* 16 <150 Installation

Nevada 2,400 18 0 79 63,960 Installation

New Hampshire 860 32 +350* 56 899 Installation

New Jersey 6,500 3 +800 448 164,112 Installation

New Mexico 1,900 22 +800 83 43,701 Installation

New York 5,000 5 +1,700 411 30,840 Installation

North Carolina 3,100 10 +1,700 137 36,771 Manufacturing

North Dakota 230 50 +150* 7 <150 Installation

Ohio 3,800 8 +900 185 8,498 Manufacturing

Oklahoma 630 37 +460* 20 <150 Installation

Oregon 2,700 14 -200 122 7,246 Manufacturing

Pennsylvania 2,900 11 -1,100 428 24,644 Installation

Rhode Island 340 45 +130* 17 328 Installation

South Carolina 1,000 29 +680 33 415 Installation

South Dakota 290 47 +240* 11 <150 Installation

Tennessee 2,800 12 +500 133 5,766 Manufacturing

Texas 4,100 6 +900 284 12,636 Installation

Utah 910 30 +620 59 1,570 Installation

Vermont 1,300 27 +990 46 4,803 Installation

Virginia 1,900 22 +1,160 123 944 Installation

Washington 2,000 20 +700 102 1,904 Manufacturing

Washington, DC 810 33 +90* 93 1,899 Other

West Virginia 370 44 +300* 11 <150 Installation

Wisconsin 1,800 24 +800 148 2,249 Manufacturing

Wyoming 340 45 +290* 10 <150 Project Development

30 march/april 2014


1,900 Washington

california total solar workers

47,223 (1/3 of all u.s. workers)

Texas

south Dakota

Quintupled # of solar jobs

Arizona

288 solar companies

colorado

56,700homes

powered by solar

homes powered by solar



Texas

+900 workers

south Dakota

Missouri

+1,600 workers

Indiana

Tripled # of solar jobs

20% of total work force

(28,510)

northeast

north carolina

+1,700 workers

Georgia

+1,800 workers

Florida

20,300homes

powered by solar

*Information from The Solar Foundation / thesolarfoundation.org

32 march/april 2014

feature

Not making any progress on its Renewable Portfolio Standard requirement, a 4-MW solar field finally gets the ball rolling in

the First State. By Robert J. Sincovich

D e l a w a r e U t i l i t y t a k e s a

Green Stand


Management and mem-bership alike at the Delaware Electric

Cooperative recently celebrated some of the early results of a solar panel installation project that involved the installation of 16,000 solar panels from Motech-Americas, now contributing to the annual elimination of 12.6 mil-lion lbs of carbon dioxide emissions at the new Bruce A. Henry solar energy farm.

This effort, completed in the latter part of 2013, is supporting this electric utility serving 84,000 member-owners in Kent and Sussex Counties in Delaware. As of late December, the field had produced some 2,400,000 kWh and is providing enough power for 500 homes to run continuously.

But, it was the initiative taken by the Delaware Electric Cooperative (Co-op), driven by its belief in renewable energy and environmental responsibility, that set the wheels in motion. Through its commitment, it brought together a team of partners, including Motech-Americas, whose panels manufactured in Newark, Del., offered the increased power and efficiencies to meet the state mandates. Also included was SunEdison, a global leader in semi-conductor and solar technology. Motech is the world’s fifth largest solar cell manufacturer, providing complete control over its supply chain and access to ensure superior cell products to deliver the required results, without the uncertainty of other options.

The Co-op members include businesses, residential and agricul-tural assets. The agriculture busi-nesses are predominantly poultry farms and irrigation groups, which can now manage part of their load via electric renewable energy, rather than bio fuels such as diesel.

State SUPPOrt“The need for this solar project was

prompted several years ago when the Delaware General Assembly intro-duced and passed legislation requiring state utilities to purchase or produce 25 percent of their energy by 2025, specifying that three percent must be generated by solar assets,” says Mark Nielson, vice president of staff services for the Delaware Electric Cooperative. “Many other states have passed similar legislation or are in the process of doing so, but as of 2012, we had no solar assets in place. And as a result, we

found that installing our own system would be the most cost-effective way to meet the state mandates, while helping the environment at the same time — so basically, this was a win-win solution.”

Based on these considerations, the Co-op decided to build its own array and deliver solar energy directly to its members. Construction began in January 2013 and the system went online in August.

QUaLItY PartnerS SunEdison was selected following a

competitive bidding process that began in late 2011. It was not a complete

turn-key project, nor was there a prior relationship between the Co-op and SunEdison. Instead, the firm’s track record of building large-scale projects was solid. As such, it was logical for them to manage the solar project. Delaware Electric Cooperative select-ed the site due to its close proximity to its point of interconnection. The Co-op then purchased the property and proceeded with the site civil work before turning the next steps over to SunEdison. It also performed all

medium-voltage work including cabling, transformation and distribu-tion circuit upgrades.

Further steps by the Co-op were to procure locally manufactured panels through Motech-Americas. They were the first and logical choice based on the firm’s focus on quality and reliabili-ty for its industry leading photovoltaic solar panels. This would enable the work to be done as efficiently and pro-ductively as possible, and help deliver the designed-in value that was required.

As part of the contractual require-ments, SunEdison employed Delaware labor for construction of the racking

34 march/april 2014

system, module installation and low voltage work. The contractor also sought the involvement of the local community college and offered work opportunities to some students. Once the civil work was completed, the site was turned over to SunEdison. The only meaningful problem encoun-tered was the weather. A very wet spring slowed progress throughout the construction period. The project was completed in August 2013 and Delaware Electric Cooperative con-tracted with SunEdison to monitor, operate and maintain the system as part of a separate three-year contract.

rOOM FOr GrOWtH This renewable energy farm will

provide members with a sustainable source of power for years to come. What’s more, Motech-America’s thousands of solar panels installed at the farm, located west of

Georgetown, will offset energy pur-chases from the wholesale market. The overall project cost approximate-ly $14 million, and the farm could eventually be expanded to 40 acres with the ability to produce 7 MW of power. It will also help Delaware Electric Cooperative to comply with the recently passed state mandates requiring utilities to invest in renew-able energy projects.

“There are very measurable bene-fits brought about by this installa-tion,” says Dave Holleran, senior manager of module sales for Motech-Americas. “This is a 4-MW solar energy farm, and through the use of our highest quality solar panels, it will elimi-nate carbon emissions in amounts comparable to taking 1,239 cars off the road. And, that’s a renewable benefit with an estimated service life of 25 years or more. By any

measure, that is a noteworthy achievement to support the envi-ronment.

“In addition,” he adds, “these solar panels were manufactured by Motech-Americas in Newark, Del., so we are not only contrib-uting to an environmentally friendly development, but we are also supporting America’s work-force at the same time.”

With more than 20 years in manufacturing modules — more than the lifetime of most solar companies — Motech experts continue to be trusted veterans in the solar industry. Strict quality control in all stages of the manu-facturing process at Motech is critical to maintaining a high record of longevity. This focus on quality and reliability helps drive revenue for developers, installers and investors.

feature


MeMBerS VOICe tHeIr tHanKS and aPPreCIatIOn

As the development of this facili-ty underwent its planning and implementation stages, Delaware Electric Cooperative found itself the recipient of strong support from its members and customers who liked the fact that the Co-op was using the Delaware-manufactured Motech panels, as well as Delaware-based labor to run its power grid.

To help maximize the extensive news value of this achievement, there was a press event held on Aug. 21, 2013, attended by numer-ous local news media. An airborne helicopter produced several TV news spots, highlighting the bene-fits of the field, the benefits to the environment and the clean energy benefits to members. There was a

clear support in the change of the renewable energy climate and strong support for the move to solar. As an added feature for its members, a special arrangement was set up for them to monitor the electrical output at the solar farm by visiting delaware.coop. This helps to put a real-world perspective on just what this accomplishment means to them individually and as a community.

Strong receptivity was also dem-onstrated due to the reduced rates that could be supported — the low-est in the state. This project didn’t allow the Co-op to lower rates, but it did not have to raise them to pay for it. Above all, the project became a textbook case of how other utili-ties could follow this path to gain the same benefits for themselves.

“Simply put,” Motech’s Holleran says, “this became a meaningful

accomplishment brought on by the right people doing the right things at the right time, with results that met or exceeded expectations. There was a strong level of fore-thought and cooperation involved in the decision-making process, and that produced the right approaches needed for this solar-based solution. For other utilities within the United States facing similar circumstances, there can be a definite value in considering the options and directions that worked so well for Delaware Electric Cooperative.”

Robert J. Sincovich is marketing com-munications strategist and owner of R.J. Sincovich Communications, with extensive experience in a variety of business-to-business categories, including solar.

rjsincovichpr.com

STATE PRIDEMembers of the Delaware Electric Cooperative, Motech, SunEdison and the local com-munity cut the rib-bon on the new Bruce A. Henry solar energy farm this past summer.

36 march/april 2014

GooGle Glass You may have seen people

walking around wearing goofy-looking glasses with what looks to be a

camera lens attached to the top. This is Google Glass, an invention from the Internet search company that brings computing to the face, no hands needed. Then again, you might not have seen it. The prod-uct has been out less than a year and only on the heads of testers

and developers. A consumer ver-sion might be available sometime in 2014.

Glass, in basic terms, is a head-mounted computer system. The device displays information, simi-lar to what you may find on a smartphone, in front of your face through a small screen attached just above your right eye’s line of vision. Glass is worn on the face like eyeglasses, although the prod-

uct does not have lenses (prescrip-tion, shaded and basic lenses are available to attach to the product). The device receives data through Wi-Fi or via a Bluetooth connec-tion. The small screen is activated through touch, head nods or by saying “OK Glass,” followed by a command. Users can scroll through options using their finger on the side of the device.

Glass can take photos and

How

Can aid tHe solar installer By Kelly Pickerel


GooGle Glass record videos, which is useful when both hands are busy. While Google originally seemed to be marketing the product to the individual consumer, many pro-fessionals have taken it to the next level. In June 2013, a sur-geon used Glass during a live sur-gery in Maine, transmitting video to a Google Hangout (a video call), opening up many more teaching opportunities. Google

has videos of firefighters using Glass to assist in training demon-strations, outlining floor plans and safety procedures.

Southern California-based com-mercial and residential installer Sullivan Solar Power saw Google Glass as an excellent way to make its own workers more efficient. The company even wrote its own app for the device, putting cus-tomer information and system

data in front of technicians’ eyes, eliminating the need for huge binders or glare-prone laptops to be hauled up on roofs at jobsites. Solar Builder spoke with Michael Chagala, director of information technology at Sullivan, to learn how Glass can help solar installers at every level work in a safer envi-ronment, and the information and advice on the next few pages comes straight from the expert.

Can aid tHe solar installer By Kelly Pickerel

38 march/april 2014

Things GooGle Glass Can do

immediaTe TroubleshooTing

Field technicians head to jobsites to troubleshoot vari-ous problems often without prior knowledge of the

installation. If they run into unfamiliar situations, live-streaming video conference capabilities can pull together the collective intelligence of experts and specialists back

in the office or at other jobsites.

Fewer maTerials

Having all information (customer reports, product specs, colleague assistance) in one central place helps so you’re not lugging manuals or

laptops up to a rooftop.

hands-Free availabiliTy

Safety around solar installs is a huge concern. Glass allows you to have both hands available when poking around in electrical boxes or climbing up ladders. The times you’ll most use Glass — video conferencing,

searching for instructions — you’ll want both hands available to point out

issues or assemble systems.

saves TimeInstead of using a separate camera

or making a phone call without having a visual, Glass completes tasks more quickly. Now you don’t have to take mate-rials back to the office, talk it over with your colleagues, reschedule a site visit

and put the customer at an addi-tional inconvenience. Everything

can be done in one visit.

Sullivan Solar Power’s Michael

Chagala demonstrates how Google Glass is

worn. The device is activated by touch,

head nods and voice.

Although much more transparent than

a solid black screen, this is how a typical “home screen” looks through

Google Glass just above your right eye.


The app does Three ThinGs for sullivan Technicians:

1) displays wearer’s agenda: All tasks for the day are listed effortlessly in front of the technician.

2) provides a lisT oF cusTomers: Scroll through the list to find phone numbers, addresses, initiate calls, initiate GPS and upload photos to the customer’s file.

3) lisTs speciFicaTions oF componenTs in use: Every product Sullivan has used over the years is listed in this app, so if a technician runs across something that is 10 years old or 2 months, they can see if it is performing as it was manufactured to do.

Sullivan solar Power aPP

The app Sullivan Solar Power developed in-house is a first-of-its-kind for the solar industry. It is not available for public download, but its program details could be dupli-cated by other solar companies.

“We think of [Glass] as a mix between an efficiency device and then also safety,” Chagala says. “It’s rare to find a device that fur-thers both of those at the same time. They seem to be opposing forces — [usually] something that’s safe now takes you twice as long to implement.”

Chagala says the next task Sullivan will use Glass in is training.“We’re going to start recording a first-person perspective for

training purposes,” he says. “An expert will perform a job duty wear-ing Glass and show it to people in training. On the flip-side is peo-ple who are in training, we’ll put them in Glass and send back a live stream of what they’re doing, allowing us to coach them from our headquarters.”

The sky is really the limit with Glass. Solar Builder hopes to see more genius ways to use it in the future!

40 march/april 2014

feature

Built-in Solar a new BipV product hopes to take

the new build and re-roofing market by storm.By Kelly Pickerel

Building-integrated pho-tovoltaics (BIPV) is the outcast from high school, not quite popu-

lar enough to make varsity. Everyone knows all about tradi-tional PV installations, but they may be missing out on BIPV’s long list of advantages just because it’s not in mainstream knowledge. MSR Innovations Inc., a new player in solar roofing based in British Columbia, recently introduced its SolTrak product to the residential market and hopes to change people’s opinions of BIPV for the better.

Getting involved with solar wasn’t even in the original plans for MSR Innovations. The found-ers, previously from the automo-tive industry, were just looking to redo one of their roofs.

“We stared at it for ages and thought, ‘This is a medieval tech-nology. What can we do to change this?’” says Tim Roddick, founder and CTO. “We started looking into the world of roofing, but it is such a huge industry that we needed to narrow the focus.”

The founders were also in the clean tech world, so they thought about changing the technology in

roofing with a clean tech aspect, and solar was the obvious choice. BIPV narrowed the focus even more.

“We do the whole roof,” Roddick says. “We do a solar component, but the majority of our roof is non-solar. If we can get a good south-facing slope, we cram as much solar on as we can. The rest of the building envelope is non-solar tiles that are of a sim-ilar nature to the solar ones in their construction.”

The SolTrak tile connects to the roof in a “Lego-like” fashion, Roddick says. First, a long extru-

sion acts as a track and is connect-ed to the roof. Tiles are then snapped into the track, locked in at each corner. The tiles consist of a backing plate, a solar cell and a polymer cover. A SolTrak system is fully integrated; it doesn’t fit into a separate roofing product or need shingles or tiles to adhere to. Requiring no tools but your hands to snap tiles into place, the MSR Innovations BIPV system is a quick installation and easily replaced or repaired.

“Our big differentiator is the design around the installation pro-cess,” Roddick says. “These days, the cost [of BIPV] is in the instal-lation. We have designed the installation to be easier and quick-er to install than previous BIPV products. We use some automotive manufacturing techniques — injec-tion molding being the key. We lay down a long extrusion and then we snap in the tiles as we go.”

Wiring and interconnection is also a quick process.

“Because it’s injection molding, we can do a lot of really intricate design details that you can’t do with any other form of roofing,” Roddick says. “The tile is raised up enough for the wiring to go underneath. We snap in the tile

into the track and then you make the connection from connectors that are attached to the next tile, and then you snap that tile down. There is a two-step process — connect and then snap-in the tile. The wiring is hidden from view.”

MSR Innovations has spent more than five years developing the durable, watertight SolTrak product. In September 2013, the company finished a 20-kW install at a seniors residence in British Columbia. Now with a successful project under their belts, those at MSR Innovations are targeting new builds and re-roofing projects. People want to take advantage of solar energy without being espe-cially flashy.

“When we first got into the roofing business, we didn’t really grasp how important the aesthetics are on a roof. It’s crucial,” Roddick says. “People do want an integrat-ed look, [but] there’s a bit of keep-ing up with the Joneses. They want it to fit, they want it to be aesthetically pleasing, but they do want people to see that they’re forward-looking and they have solar on their house. If you went [with a] bare-boned asphalt roof with solar slapped on top, it would be as quick as our product, [but]

quite a bit uglier and not an inte-grated system.”

When considering the overall cost of a new roof with traditional solar installed, BIPV can be cheaper. With a BIPV system, there are no mounting hardware or asphalt/tile installation costs.

“We’re not that much different from a typical solar panel provider other than we’re not really restricted by space,” Roddick says. “We have lots of room, so we go for dollar per watt for our solar purchase. We rare-ly fill the entire southern face of the roof [with solar]. If we need more solar, we yank off a non-solar tile and put on a solar one. There is lots of real estate up there.”

Roddick believes residential solar is really an untapped market.

“One of the biggest advantages of solar is generating power where you use it,” he says. “Residential sales, I think, are in their infancy. It’s an expanding market.”

If given the chance, BIPV could be a strong leader in the residential market.


solarBuildermag.com | 41

Built-in Solar @solar_builder

solarbuildermag.com

SNAP-ON SOLARSolTrak tiles were

installed on the

roof of a seniors

residence in

Canada, providing

20 kW of power.

42 march/april 2014

last word recent news from solarbuildermag.com

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Jr motorsports, management company for nascar driver dale earnhardt Jr., recently installed 836 solar mod-ules on its race shop roof in moorseville, n.c. the system will reduce Jrm’s grid power usage by 44 percent.

the electric Power research institute (ePri) launched a study in february on the transformation of the electric power grid, understanding that the rapid rise of distributed energy resources (like solar panels) could change the structure of the grid.

“if we are going to realize the full value of these [distributed energy] resources, while at the same time continue to provide affordable and reliable electricity, we need to integrate them into every aspect of grid planning, operations and policy,” said dr. michael Howard, president and ceo of ePri.

ePri outlined an action plan for all stakeholders, including updating interconnection rules and communication standards, deploying advanced distribution and reliability technologies, integrating distributed energy resources into grid planning and operation, and informing policy and regulation to enable transformation to the integrated grid. ePri also unveiled an initiative to provide stakeholders with the tools necessary to develop this.

see a full summary of this report and the ePri’s suggestions on solarbuildermag.com.

solectria inverters will power a recently completed 1.43-mw ground-mount system at fort carson, an active u.s. army installation in colorado. infinity construction services and Quanta services built the project.

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solarbuildermag.com march/april 2014 behind the scenes at ... · dan sisko [email protected]...

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