sunrun field quality assurance scorecard - aee...

Sunrun Field Quality Assurance Scorecard

Danny HytowitzField Technical Trainer

Field OperationsSunrun

Tuesday, January 19, 2016San Diego, CA


The Sunrun QA Scorecard Concept

Interpreting the Scorecard


• Question-level performance data is critical to tracking crew progress.

• 54 criteria on the scorecard.

• Each item on scorecard should be scored as objectively as possible.

‒ “Good” is not reportable

‒ “3 out of 5” is more reportable, but still subjective

‒ Pass/Fail for a total of 5 points is both objective and reportable

Sunrun QA Scoring Criteria

• Pass – Criteria satisfied.

• Fail – Criteria not satisfied.

• Substantial Fail – Issues that will likely lead to critical failures: e.g. fire, system damage, roof leak, etc.

• Missing – the photos do not accurately document the issue.

• N/A – the criteria is not applicable to the system.


• Priority Criteria = crucial items. If one PC is failed, entire project fails, regardless of score.

• Passing project = Score is 85% or above and no PC failed.

• There will always be comments for failed questions, but some comments are just notes (e.g., “There is no external DC disconnect.”)

Priority Criteria (20 of 54 items)

01-02: Array Characteristics Match

EPC

01-04: Shade Profile Match EPC

02-01: Array Flashing

02-02: Mounting System Installation

02-03: Mounting System Grounding

03-01: Module Grounding

03-03: Modules Consistent With EPC

04-01: DC Conductor Support

04-02: DC Conductor Exposure

06-03: Conduit Support Flashing

06-04: Conduit Penetration Flashing

07-01: DC Disconnect Wiring

07-03: DC Disconnect Enclosure

08-04: DC Conductor Fusing

10-01: AC Disconnect Enclosure

10-06: AC Disconnect Fusing

(Supply Side)

11-01: MSP Grounding

11-03: 125% Rule

11-05: 120% Rule

12-03: System Safe and Operational

Most Common Failures

Item % Fail

Sunrun Service Sticker 50%

Interconnection Labels 38%

DC Disconnect Labels 27%

Sunrun Meter Tag 25%

AC Disconnect Labels 14%

Under-Array Wire Mgmt 13%

Inverter Installed in Sunlight 13%

Wire Color Convention 11%

Conductor UV Exposure 10%

Solar Breaker Location 9%

Junction Box Wire Mgmt 8%

125% Rule 8%

Conduit Penetration Flash 8%


Scorecard Demo

02-01 Are all array attachment roof penetrations properly flashed?

Evaluation Guidelines: Must comply with IBC standards; must comply with product manufacturer installation instructions; industry standard practices are used appropriately and all mounting and racking is securely installed.

PASS

03-01 Are modules electrically grounded in accordance with manufacturer’s installation instructions?

Evaluation Guidelines: inspector must look up manufacturer spec (examples: lay in lug, weeb)

PASS

04-02 Are conductors safe from physical damage (not in contact with the roof)?

Evaluation Guidelines: Conductors may not contact roof surface or be in jeopardy of damage by sharp objects (digging into conductor insulation); Conductors that are sagging within 1" of the roof are unacceptable

FAIL: Conductor in contact with the roof surface.

05-04 Is the junction box (if metallic) grounded with EGC continuity?

If this is a microinverter system and the EGC also serves as a GEC, the EGC/GEC connection must be irreversibly spliced. For non-micro systems, the EGC does not need to be irreversibly spliced.

N/A

05-05 Is the junction box properly supported?

Junction box may not be attached directly to the roof unless integrated flashing is used (e.g. Soladeck); junction box can be attached to rail either underneath or outside of the array

PASS

06-04 If conduit is routed through a roof surface, is that penetration properly flashed?

Flashed per IBC standards; conventional flashings under 1-2 courses of roofing material

FAIL: • Flashing is not installed far

enough under the shingle. • Oatey-style flashing is not allowed

by Sunrun.

07-05 Are the DC labels required by NEC installed on the DC disconnect?

Label identifying the DC disconnect.NEC 690.17 label: WARNING ELECTRICAL SHOCK HAZARD. DO NOT TOUCH TERMINALS. TERMINALS ON BOTH THE LINE AND LOAD SIDES MAY BE ENERGIZED IN THE OPEN POSITION.NEC 690.53 label: Rated MPPT Current, Rated Maximum MPPT Voltage, Maximum System Voltage, Short Circuit Current.

FAIL: NEC 690.53 label is installed, 690.17 is not.

08-01 Do the conductors (AC and DC) use the correct color convention for each terminal and are they wired appropriately?

Grounded: grey or white. Ground: green or bare. Ungrounded: any other color. Wiring technique should include service loops; all conductors securely attached to terminals.

FAIL: White wires used as DC conductors in an ungrounded system.

(ABB PVI-6000 inverter)

10-03 Are AC conductors from the utility connected to the line side (top) of the AC disconnect?

Are AC conductors from the utility connected to the line side (top) of the AC disconnect?

MISSING

11-03 Is the solar interconnection breaker (or AC disconnect fuses) sized according to the inverter(s) maximum continuous output current x 1.25?

Overcurrent protection to follow increments in NEC 240.6; 15,20,25,30,35,40,45,50,60,70,80,90,100 Amps

FAIL: 6000 W inverter, 240 V. Output current = 25 A25 A x 1.25 = 31.25A. 35A breaker required

Your Turn!

• Review the photos and assign Pass, Fail, Missing or NA for each question on the scorecard.

• Write comments for any failed criteria.

Audit Review

• Review and discuss all non-Passing items.

Scorecard Section 01: Array


EPC (stated) Azimuth 182 Tilt 25Actual (measured) Azimuth 180 Tilt 27


• 01-01 Remaining life of roof should be ~15 years

• 01-02 Are all array characteristics consistent with the EPC Addendum?

• Fail. UV granules worn away, fibers showing

• Pass


Above original shade report vs recent site visit below


• 01-03 Is the array EGC (Equipment Grounding Conductor) sized and installed appropriately?

• 01-04 Is the shading profile consistent with the EPC Addendum?

• Pass

• Fail. Shade impact is more significant than originally measured (not long ago)

Scorecard Section 02: Mounting System


• 02-01 Are all array attachment roof penetrations properly flashed?

• 02-02 Was the mounting system installed according to the manufacturer guidelines?

• Fail. Array flashings are not installed correctly, i.e., not installed flush with the shingles.

• Fail. There are at least two loose mid clamps.


• 02-03 Is the mounting system properly grounded?

• Pass (picture shown earlier with lug)

Scorecard Section 03: Module


• 03-01 Are modules electrically grounded in accordance with manufacturer’s installation instructions?

• 03-02 Are modules mechanically mounted in accordance with manufacturer's installation instructions?

• Fail. WEEB installed incorrectly (bent/damaged).

• Fail. Modules not supported in designated areas


• 03-03 Are modules consistent with the EPC Addendum?

• Missing. Cannot confirm module manufacturer/model from the photos.

Scorecard Section 04: DC Conductor


• 04-01 Are conductors protected from UV damage?

• 04-02 Are conductors safe from physical damage?

• Fail. Conductors exposed to UV at j-box entry.

• Fail. At least one conductor is laying on the roof. Others not well-supported -hanging low.


• 04-03 Are DC conductors properly managed?

• 04-04 Does wire management technique avoid any sharp bends in conductors?

• Fail. Conductors exposed to UV at j-box entry.

• Pass

Scorecard Section 05: Junction Box


• 05-01 Are all array conductors entering the junction box (or conduit) properly?

• 05-02 “Are conductors correctly managed within the junction box?”

• Pass

• Fail. Wire nuts in the j-box are not direct-burial rated. Should be replaced with wet-rated wire nuts or similar.


• 05-03 Is junction box rated to a minimum environmental rating of NEMA 3R, and does it have a drainage hole?

• 05-04 Is the junction box (if metallic) grounded with EGC continuity?

• Pass

• N/A


• 05-05 Is the junction box properly supported?

• Fail. Junction box is screwed to roof, not properly supported above roof also may cause leaks roof damage.

Scorecard Section 06: Conduit


• 06-01 Are conduit and fittings rated for the environment and properly installed? Is conduit properly supported?

• 06-02 Are conduit runs aesthetically pleasing?

• Fail. Strut is not appropriate material for conduit support.

• Pass


• 06-03 If conduit supports penetrate the roof, are they flashed?

• 06-04 If conduit is routed through a roof surface, is that penetration properly flashed?

• N/A

• Fail. Oatey-type flashing not allowed by Sunrun.Flashing not installed under enough courses of shingle; sides of flashing are exposed.


• 06-05 If conduit is routed through a wall surface, is that penetration properly sealed?

• 06-06 “Is metallic conduit grounded?”

• Missing.

• Missing.

Scorecard Section 07: DC Disconnect


• 07-01 Are all ungrounded conductors broken in the DC disconnect? Are all grounded conductors unbroken?

• Fail. Rooftop disconnect does not break both conductors; this is an ungrounded system.

• 07-02 Is DC disconnect wired correctly?

• Pass


• 07-03 Is the DC disconnect appropriately sized and rated for the environment?

• 07-04 Is the enclosure grounded with EGC continuity to inverter?

• Missing

• Pass

• Pass

• 07-05 Are the DC labels required by NEC installed on the DC disconnect?

Scorecard Section 08: Inverter


• 08-01 Do the conductors (AC and DC) use the correct color convention for each terminal and are they wired appropriately?

• Fail. White wires used for DC conductors, but this is an ungrounded system. Per NEC 200.6, white wire is reserved for grounded current-carrying conductors.

• 08-02 Is the inverter(s) consistent with the EPC Addendum?

• Pass


• 08-03 Is the grounding electrode conductor (GEC) a minimum #8 conductor and continuous or irreversibly spliced to common system/structure grounding electrode?

• Pass

• 08-04 Are individual DC strings provided with properly sized DC series fuses, if required?

• N/A


• 08-05 Is the inverter (and all AC/DC disconnects) grouped in a logical, code-compliant, and aesthetically pleasing configuration?

• Pass

• 08-06 Is the inverter installed out of direct sunlight?

• Pass

• 08-07 Is the inverter installed according to the manufacturer's guidelines?

• Pass

Scorecard Section 09: Monitoring

Scorecard Section 09: Monitoring

• 09-02 (if applicable) Is the manufacturer's monitoring device appropriately installed?

• Fail. Monitoring not registered to Sunrun

• 09-03 Is the meter installed between the inverter and AC disconnect?

• Pass

• 09-04 Is the meter ring (if applicable) and Sunrun tag installed?

• Fail. Sunrun meter tag is not installed.

Scorecard Section 10: AC Disconnect


• 10-01 If an AC disconnect is used, is it a blade-style disconnect, sized correctly, and appropriate for the environment?

• 10-03 “Are AC conductors from the utility connected to the line side (top) of the AC disconnect?”

• Pass

• Fail. Conductors from the utility are connected to the load side of the AC disconnect.

• 10-02 Is the AC disconnect enclosure grounded with EGC continuity from inverter?

• Pass


• 10-04 Is the AC disconnect appropriately labeled?

• 10-06 If the inverter output is connected to the supply side of the main service panel, is the AC disconnect fused and rated for a minimum of 60 amps?

• Pass

• N/A

• 10-05 Are all ungrounded conductors broken in the AC disconnect? Are all grounded conductors unbroken?

• Pass

Scorecard Section 11: Interconnection

• 11-01 Is the equipment grounding conductor connected to ground?

• Pass

• 11-02 Are the NEC required interconnection labels installed?

• Pass


• 11-03 “Is the solar interconnection breaker (or AC disconnect fuses) sized according to the inverter(s) maximum continuous output current x 1.25?”

• SB5000TL max output current = 22A. 22 x 1.25 = 27.5. 30A breaker.

• SB3000TL max output current = 15A. 15 x 1.25 = 18.75A. 20A breaker.

• Combined back feed breaker = 27.5 + 18.75 = 46.25A. 50A breaker. Combined back feed

breaker is undersized.


• 11-04 If the point of interconnection is on the load side, is the solar breaker properly installed?

• If the point of interconnection is on the supply side, are the conductor splices suitable for the situation?

• Pass

• 11-05 If the point of interconnection is on the load side, does the sum of the solar breaker and main breaker not exceed 120% of the bus bar rating?

• Pass

Scorecard Section 12: General

• 12-01 Was the work site left in a clean condition (i.e. no trash and no materials left behind)?

• Pass

• 12-02 Is the "Sunrun service sticker" securely attached and clearly visible?

• Pass

• Fail. No Sunrun Service Sticker was observed

• 12-03 Was the system found in a safe and operational state?


Questions?

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