WILEY WEEB® 101
Bonding, Grounding and Wire Management
In the beginning
•
•
•
•
•
•
•
Founded in 2006 by Brian Wiley
Licensed solar installer
Needed low cost solution for faster installation and less copper wiring
Invented WEEB concept to bond and ground PV arrays
Invented Conduit Entry Box for transition from PV array into conduit
Invented Cable Clips for wire mgmt
Burndy acquired Wiley as a product line in 2011
NEC Safety Overview
• Any metallic parts of a PV array that could become live or
energized shall be bonded.
• Bonding is connecting metallic parts so as to maintain
electrical conductivity.
• Bonded parts of the PV system shall be connected to earth
(grounded) by qualified persons in accordance with the
National Electrical Code (NEC).
Bonding vs. Grounding
Bonded (Bonding) – Connected to establish electrical continuity and conductivity.
•
Grounded (Grounding) – Connected to ground or a conductive body that extends the
ground connection.
Courtesy: Home Power Magazine
•
WEEB® washer bonding both PV
module frames to mounting rail
Per NEC 690.46, #6 AWG will
commonly be required as
EGCs for module frames.
NEC 690.43
Equipment Grounding
NEC 690.43 A
Exposed metal parts of PV module frames and electrical
equipment must be connected to an equipment grounding
conductor (EGC).
NEC 690.43 B
An equipment grounding conductor (EGC) must be installed
between the PV array and the associated equipment.
NEC 690.43 C and E
Devices listed and identified
for grounding the metallic
frames of PV modules or other
equipment shall be permitted
to bond the exposed metal
surfaces or other equipment to
mounting structures.
Devices identified and listed
for bonding the metallic frames
of PV modules shall be
permitted to bond the exposed
metallic frames of PV modules
to the metallic frames of
WEEB® washer bonding both PV adjacent PV modules.
module frames to mounting rail
Previous Approaches to Grounding
Lay-in Lug (costly and labor intensive)
Intended for use on conductive surface.
•
Requires surface prep: sandpaper and anti-oxidant paste.
•
Stainless steel screw should not be used as conductor.
Courtesy: nmsu.edu
•
Gray Areas in Grounding
NEC language is complicated / confusing.
•
Any metal that may become energized and likely to be in
contact shall be grounded.
•
Each installer’s experience / workmanship will vary.
•
Authority Having Jurisdiction (AHJ) may have different
interpretations based on their local guidelines.
•
Variety of grounding methods: mistakes will happen.
Courtesy: nmsu.edu
•
Grounding Violations
Dissimilar metals leads to
galvanic corrosion
Courtesy: nmsu.edu
Indoor rated Lay-in lug on rail with no
surface prep and thread forming screw
vibrated out: no grounded connection.
WEEB® Washer Solution
Simple and low cost method to bond PV module
frames and racking together in order to reduce time,
labor costs and amount of copper wiring.
What’s a WEEB® Washer?
Most widely recognized and accepted device for bonding
PV module frames to metal mounting rails.
®
WEEB
Washer, Electrical Equipment Bond
WEEBs, Lugs and Jumpers – Safety Certifications
• WEEBs – UL 467 Listed and UL 2703 Recognized
• WEEB Lugs & Jumpers – UL 2703 Listed
• WEEBs for bottom mounting – Soon to be UL 2703 Listed
Suitable for all markets
Residential
Commercial
Utility scale
250 MW Project
1.1 million modules
1.1 million WEEBs
Suitable for numerous applications
Ground Mount
Mount
Pitched Roof
Pole Mount
Flat Roof
How the WEEB® washer works
• Inserted between module frame and mounting rail.
• WEEB® washer teeth pierce through anodized coating for
excellent conductivity and prevents oxidation.
• Bonds PV module frames to metal racking structure.
PV
module
frame
Mounting
rail
WEEB®
washer
Pop Quiz
How is a WEEB® washer equivalent to #6 copper EGC?
A.) Able to withstand 1000 Amps for 2 seconds
B.) Able to withstand 1200 Amps for 4 seconds
C.) Able to withstand 1530 Amps for 6 seconds
Embedded Teeth Marks
Points of
electrical
connection
PV module frame (bottom)
1530 Amps is
transferred
through 4 teeth
Mounting rail (top)
Why use WEEBs?
Reduces overall system cost and improves profitability
• Less time at job site
• Less copper
Only the mounting structure is grounded, since modules are
bonded to rails: making it one big piece of metal.
headquarters
in Mountain View, CA
using WEEB®
Benefits
Safe, durable and reliable
• UL 467 Listed for Grounding and Bonding
• UL 2703 Recognized for mounting systems and clamping devices
• Highly resistant to corrosion
Robust – 1530 Amps for 6 seconds (equivalent to #6 copper)
using WEEB®
Clamping Force
Before applying torque:
WEEB® washer teeth protruding
After applying torque
WEEB® washer fully embedded
into module frames and rail making
conductivity
How many WEEBs do I need?
Rule of thumb: 1 WEEB® per module
WEEB Compatibility Sheet
Compatible Racking Manufacturers
WEEB® Bonding Jumpers
• Maintains electrical bond across mechanical splices
• WEEB® washer with tin plated, copper braided cable: #6 AWG
• Install with WEEB® teeth “biting” into Aluminum surface
WEEB® Lugs for Grounding
• WEEB® washer and tin plated, copper lay-in lug
• Allows for one #6 AWG copper conductor
or two #10 AWG or two #12 AWG conductors
WEEB® Lugs overhead view
WEEB® LUG
Locations
SnapNrack rail and WEEB-PMC
WEEB LUG
WEEB-PMC
DPW rail with WEEB-DPR
WEEB LUG
WEEB-DPR
Cable Clips for Wire Management
•
•
•
•
•
Keeps cables off roof
Prevents damage to cable insulation
Clean & aesthetically pleasing
Corrosion resistant stainless steel
Deters rodents from chewing on cables
Cable Clips for Rails
Wire management – attachment to the rail
• SnapNrack
• DPW Power Rail
• Unirac Solarmount
• ProSolar Roof Track
• Ironridge XRS & XLS
Holds trunk cable and drop cable for Enphase M190, M210, D380
• Wire diameter 9.3 – 11.0mm
Cable Clips for module frames or purlins
•
•
•
•
90 degree cable clip for versatile orientations
No tools needed for fast and easy installation
Smooth edges to prevent damage to insulation
UL 1565 Listed
Conduit Entry – ACE Box
• Simple array to
conduit transition
• Polycarbonate
Makrolon: High
Temperature
Rated 125ºC
• NEMA 3R rated
• UL 1741 Listed
Combiner Box – Internal View
ACE Box Mounting Possibilities
Rail Mounted
Top of Pole
PV System Installation Overview
R & D – 3D Microscope Analysis
Acceptable for Multiple Use
WEEB-DSK embedment marks
after 1st fastening pre-test.
WEEB-DSK embedment marks
after 4th fastening pre-test.
WEEB-DSK embedment marks after
5th fastening: post High Current
Test at 1530 Amps for 6 seconds.
Integrated Grounding Midclamps
WEEB integrated into midclamp
WEEB becomes invisible
Preassembled WEEB
on integrated midclamp.
Retention feature
keeps midclamp above
rail for fast and easy
module installation.
Wiley – not just WEEBs
WEEB Washers
Integrated Grounding Midclamps
Wire Mgmt
Lugs
Combiner Boxes
Braid
UL 2703 – PV Racking & Clamping Devices
• UL 2703 1st edition ANSI approved as of Feb. 2015
• Evaluates racking structure for ground/bonding paths, mechanical
strength and suitability of materials.
• Racking mfrs. may have their “systems” evaluated to simplify inspection
issues
– System consists of Rail, Bonding/Grounding device and PV module
Moving Forward
•
Provide PV grounding plans and full documentation to
inspector in advance.
•
Proper training and education are vital, e.g., NABCEP,
SEI, Solar ABC’s, John Wiles, Bill Brooks, Mike Holt, etc.
•
Future of PV industry
depends on safety,
reliability and quality
workmanship on
installed systems:
which may last up to
30+ years!
Other possible uses for WEEBs
Box Cutter WEEB®
Wiley Cable Clip – Money Clip
WEEB® Lug Bottle Opener
WEEB® Jewelry
Visit our Wiley website for more info
www.burndy.com
Thank You!
Harley Haney
(M) 845-633-2065
hhaney@burndy.com