Stand-alone Power System (SPS) CASE STUDY APPLICATION PACK A case study is a representation of your “Best Work” so please pay particular attention to the quality of your installation. Are you using Best Practice methods? Have you included the right photographs and are they clear? SPS Case Study Checklist Assessment Date: Installer to fill in green section Note: Failure to supply any information listed below may result in a failure of the case study. Application of a new case study will incur additional fees. No. D-01 D-02 D-03 D-04 D-05 D-06 D-07 D-08 D-09 D-10 P-01 P-02 P-03 P-04 P-05 P-06 P-07 P-08 P-09 P-010 P-011 P-012 P-013 P-014 L-01 L-02 L-03 L-04 L-05 L-06 L-07 L-08 L-09 L-010 L-011 L-011a L-012 L-013 L-014 L-015 L-016 L-017 AC-01 DC-01 DC-02 GAL01 Item Description Application Form Electrical License / Name Matched / Date Insurance Certificate / Current Case Study Requirements Form Installation, Testing and Commissioning – Fully completed Wiring Diagram / Components listed – Fully completed System Performance Est-ANNUAL, BEST & WORST Kwh Engineering Cert for Frame/ Rail System Mounting System-Rail foot spacing form System Load Design – Fully completed ID Photograph Solar Array on Roof-General view Roof Fixing brackets / fixing of rails to roof Module Earthing device Rail Earthing device Rail Joiner / Splice kit-Earthing rail to rail DC Isolator / String Fusing- Internal Roof Penetration- Main Cable Entry Point DC cable ID / Protection & Reticulation Panel Cabling- Under Module Secured Inverter & Isolators--Broad View DC Isolators (Main)--Internal Wiring MSB /Upstream Switchboard / Meter Panel Close up of batteries (showing link connections) "Warning-Dual Supply " Label "Normal Supply Main Switch" Label "Solar Supply Main Switch" Label "Warning-Dual Supply-DB " Label “Inverter Location “ Label (if req) “Warning Hazardous Dc Voltage” (J-box) “PV” Label & "Solar Array on….Voc…..Isc…." “PV Array DC Isolator “ Label “Warning-Multiple DC Sources” Label “SOLAR” marked on conduit "Shutdown Procedure" Label “Site Plan Layout” Drawing Electrolyte Burns & Danger Risk of Battery Explosion. Any other signage that may be required by local distributer. WARNING Uninterruptible Power Supply System Main Battery Isolator Earth Stake with Label Warning, This premise contains….(Required In Victoria) AC isolator meets Max Inverter Output Current? DC Isolator Rating meets Voc/Isc requirement? DC Isolator appears to be Wired Correct? Galvanic Isolation sighted /evidence? Installer Assessor Comments by Assessor Instructions The case study submission can only be made by a provisionally accredited person seeking to upgrade to full accreditation or by a fully accredited person seeking points as part of the CPD program. If you are applying for a Design Only or Design & Install accreditation then your name is the only name that can be present on the circuit design drawings and Performance estimate forms. (Design forms and /or drawings designed by others will not be accepted) If you are applying for any type of “Install” accreditation you must be the person who undertook the installation (you cannot sub-contract to others) therefore your name shall be the one appearing on all relevant documentation including Installation & Commissioning Sheets. All Photographs, design information and installation & commissioning sheets must be from the same installation. Multiple installation pictures will render the case study void and a new case study will be required. CASE STUDY ASSESSMENT RATINGS Competent / Not-Yet Competent / Fail Competent: An applicant will be deemed competent when the assessor is satisfied that there is sufficient evidence that the installation has been conducted to all current and relevant standards and guidelines and that supporting evidence has been sighted as evidence of this compliance. Not yet Competent : An applicant will be deemed not yet competent when the assessor is not satisfied that there is sufficient evidence that the installation has been conducted to all current and relevant standards and guidelines and that insufficient supporting evidence has been sighted as evidence of this compliance. Failed: An applicant will be deemed failed/ rejected in the following circumstances: The applicant has repeatedly failed to submit the required information A Fail result will require the applicant to make a new submission and additional charges will apply. The Assessor deems that the evidence provided shows a PV installation that may be mechanically or electrically un-safe and may cause physical harm to people or property. The applicant has submitted a false electrical license or is not licensed to carry out the work. The applicant has not met the minimal training standard / completed the necessary training units as required to make the CS application. The assessor deems that the PV installation is in clear breach of AS/NZS 3000 wiring rules. Accreditation Application Name: ...................................................................................................................... of .............................................................................................................................. [ Business Name ] Address: ................................................................................................................................................................... Ensure ALL written entries are legible State .............................. Postcode ........................ Work Ph ............................................ Work Fax ............................................ Mobile ............................................ email ....................................................................................................................................................................... 1. Accreditation Upgrade I hereby apply for Upgrade of Full Accreditation. Accreditation type: [ Tick at least one ] □ □ □ SPS PV Design only SPS PV Install only □ □ □ GC PV Design only GC PV Install only GC PV Design and Install Licensed Electrician № .................................................. SPS PV Design and Install Legible photocopy attached NOTE : Upgrade to Full accreditation is required within three months of provisional award date. Extensions up to a maximum of a further 3 months may be available on application. 2. Payment $880 (incl GST) Payment by cheque: my cheque is attached Payment by credit card: ( payable to Clean Energy Council ) □ Amex □ MasterCard □ Visa Amount $ ................... * Credit card surcharges will apply Card number: .............../ ............../ .............../ ............... Expiry Date: ......................... Amount $ ................... Name on Card: ............................................................... Card Signature: .............................................................. The Accreditation Fee ( less a processing charge ) will be refunded if the application is unsuccessful . If your Accreditation expires prior to this application, you must apply, in advance, for an extension. 3. Insurance Current public liability insurance is held with ........................................................................................................... ( attach copy of Certificate of Currency ) Policy Number ……………………………………....... 4. Declaration to the value of $ ………………………….. Confirm each item by ticking the checkbox, then complete and sign the declaration. I represent and warrant that □ □ □ all information contained in and attached to this form is correct and not misleading by inclusion or omission; I have read the Clean Energy Council Terms and Conditions ( attached ) and the Clean Energy Council Code of Conduct ( attached ) and agree to be bound by those Terms and Conditions and the Code of Conduct upon signature of this form; I understand that acceptance of my application is at the discretion of the Clean Energy Council and I agree to abide by any rule the Clean Energy Council may make with respect to Accreditation. Application signed ................................................................................................ Date ................................ Please return application to: Clean Energy Council Level 15, 222 Exhibition Street, Melbourne VIC 3000 Phone: 03 9929 4141 email: accreditation@cleanenergycouncil.org.au Your name, address and contact details will be published by the Clean Energy Council on its website and sent to the state agencies for the purpose of identifying you as an Accredited Installer of renewable energy systems. For further information about our use of your personal information and your right of access to it, please contact a member of the accreditation staff accreditation@cleanenergycouncil.org.au Document Accreditation Application.docx Doc - Iss No. 2.3 Authorisation CEC Accreditation Manager K. Allsopp Page 1 of 1 Date 20 November, 2012 Accreditation Case Study overview The Accreditation process requires that case studies are submitted when moving from Provisional to Full Accreditation AND when renewing Full Accreditation. This is to ensure compliance with current Australian Standards and that Design/Installation skills are maintained. The power system must: have a minimum rating of 450W PV or 1kWh/day for systems utilising other energy sources have been designed and installed in the previous two years have a load design base on a variable load i.e. not a telecommunications system, battery back-up (UPS) be for a fixed structure i.e. not a mobile structure, boat, caravan, trailer, etc. not have been previously submitted to the CEC for accreditation purposes Case studies should be submitted separately (as the installations are completed) before the due date to enable case study assessors to assist with any non-compliance. Stand-alone power systems (SPS) case studies The AS/NZS 4509.2 Design Guidelines must be used as the basis for all SPS design work. This DOES NOT preclude the use of commercial design software or purpose-built spreadsheets, BUT the designer must be aware of any requirements or recommendations that are not directly addressed by the software used. Additional information is required to cover all aspects of AS/NZS 4509.2 System Design The power system installation must comply in ALL respects to relevant standards, legislation and regulations. Directly applicable standards are: AS/NZS 3000 AS/NZS 4509.1 AS/NZS 4509.2 AS 4086 AS/NZS 5033 AS 2676 AS 3011 AS/NZS 3010 Wiring Rules SPS Safety and Installations SPS System Design Secondary Batteries for use with SPS – installation and maintenance Installation of photovoltaic (PV) arrays Guide to installation, maintenance … of secondary batteries in buildings Electrical Installations – Secondary batteries installed in buildings (LV batteries) Electrical Installations – Generating sets NOTES 1. Accredited personnel must be up-to-date and familiar with all Standards and Guidelines. 2. The case study documentation must also include: Case study form/s completed – all installed equipment listed System Performance Load Design – AS/NZS 4509.2 Section 5 Appendix A – major system parameters. This information must be included as part of the design documentation. A copy of the System Commissioning checklist, covering all applicable standards and guidelines should be provided with the case study documentation. Installation photographs that show all installed equipment – general layout with detailed views of Major components, System wiring, Component labelling and Safety signage System Connection diagram – A circuit diagram showing components hook up, cable sizing and polarity, ratings of all components including make and model of breakers and isolators for the installed system Document: D-02 Electrical License Copy of Your Electrical License Please submit a clear copy (Front & Back) of your current Electrical workers License. Document: D-03 Insurance Certificate Please submit a clear copy of your current Public Liability Insurance (Minimum $5 million Insurance cover) P-01 Installer Photo for ID card Accreditation Case Study Stand-alone Power Systems Document D-04: - Case study requirements A stand-alone system design is required for each installation. Minimum requirement – complies with AS/NZS 4509.2 SPS Design Guideline. The installation must comply in all respects to relevant standards, legislation and regulations. Refer to Accreditation Case Study Overview for additional detail of requirements. DESIGNER …………………………………………………………………………...... INSTALLER …………………………………………………………………………...... Accred No. ………………………. Address …………………………………………………………………………………………….. State ………………………. …………………………………………………………………………………………….. Postcode ………………………. Phone ……………………………………………………………… Mobile …………………………………………………………………… Email ………………………………………………………………………………………………………………………………………………….. Accred No. ………………………. Address …………………………………………………………………………………………….. State ………………………. …………………………………………………………………………………………….. Postcode ………………………. Phone ……………………………………………………………… Mobile …………………………………………………………………… Email ………………………………………………………………………………………………………………………………………………….. SYSTEM OWNER ……………………………………………………………………. Install date / / Address …………………………………………………………………………………………….. State ………………………. …………………………………………………………………………………………….. Postcode ………………………. Phone ……………………………………………………………… Mobile …………………………………………………………………… Email ………………………………………………………………………………………………………………………………………………….. LICENCED ELECTRICIAN ………………………………………………………… Lic. No. ………………………. Phone ……………………………………………………………… Mobile …………………………………………………………………… ELECTRICAL CONTRACTOR …………………………………………………… Reg. No. ………………………. Phone ……………………………………………………………… Mobile …………………………………………………………………… Installation, Testing & Commissioning Sheet General WARNING: Where short circuit currents are required, follow AS/NZS 5033 Appendix D for the steps that shall be undertaken to measure the short circuit current safely. NOTE: Some projects require that short circuit currents are recorded as part of the contractual commissioning; otherwise a record of the actual operating current of each string is sufficient. This could be done by using the meter on the inverter or by using a clamp meter when the system is operational. Testing of the battery load currents could be done by using the meter on the inverter or by using a clamp meter when the system is operational. Insulation resistance measurement WARNING: PV array dc circuits are live during daylight and, unlike a conventional ac circuit, cannot be isolated before performing this test. Follow AS/NZS 5033 Appendix D4 for the steps that shall be undertaken to measure the insulation resistance safely. D-05 Installation, Testing and commissioning (sample) SYSTEM TYPE (Please indicate which system has been installed) DC Coupled Battery Storage System. AC Coupled Battery Storage System. SYSTEM COMPONENTS PV Manufacturer & Model number. Number of modules in series in a string Number of PV Array strings in parallel PV Inverter - Manufacturer & Model number. (Battery Inverter) Manufacture ………………………………………………………… Model ……………………………. Inverter size. (kW) Inverter only Inverter/Charger Interactive inverter Ratings Continues …………..……W ½ Hour ……..…………W Surge ………..……….W PV Inverter - Manufacturer & Model number. (AC Coupled) Manufacture ………………………………………………………… Model ……………………………. Inverter size. (kW) Isolating transformer Ratings No. Installed ………………. No. of MPPT’s ……………ea. Rated AC Power (W) …………… Max DC Max DC MPPT Power (W) …………… Input (V) …………….. Range (V) …………….. Non-isolated Solar array Regulator/Controller DC coupled systems Manufacture ………………………………………………………… Model ……………………………. Number of Regulators/ Controllers Ratings Regulator MPPT Controller Max if MPPT Current (A) …………… max Power (W) …………… for MPPT String Voltage (V) …………… Battery Manufacturer & Model number Manufacture ………………………………………………………… Model ……………………………. Battery Type. FLA AGM GEL Sealed LiFePO4 VRLA Ratings System Battery Capacity No. of Voltage (V) …………… Voltage (V) …………… (Ah C100) ……………. Strings ………… Battery Charger Manufacture ………………………………………………………… Model ……………………………. Type Constant voltage (transformer type) Constant current (electronic) Inverter charger separate Charger Generating Set Manufacture ………………………………………………………… Model ……………………………. Type Petrol/Ethanol Diesel/biodiesel LPG/other Ratings Capacity Expected runtime (kVA) …………… Best month (hrs) …………… Worst month (hrs) …………… Wind Turbine Manufacture ………………………………………………………… Model ……………………………. Ratings Rated Power(W) …………… at Wind speed (m/s) …………… Hub Height (m) …………… Micro Hydro Manufacture ………………………………………………………… Model ……………………………. High head systems (impulse turbine) Low head systems (reaction turbine) Output Power (W) …………… Output Power (W) …………… at Gross head (m) …………… at average flow rate (l/s) …………… Additional information ………………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………………. ………………………………………………………………………………………………………………………………………………………………………. INVERTER INSTALLATION DETAILS Solar Inverter is installed as per manufacturer’s Specification. PV array isolator mounted adjacent to the inverter. AC Isolator is mounted on output of the inverter. (where required) Lockable AC circuit breaker mounted within the (Rating:………………………………..Vdc, …………….Adc) switchboard to act as the inverter main switch for the PV/inverter system (Rating ………….. A ) Battery Inverter is installed as per manufacturer’s Specification. Main battery isolation device mounted near inverter. (eg. Fuse switch or DC Circuit Breaker) PV ARRAY INSTALLATION DETAILS PV array tilt. ……………………° PV array orientation. ……………………° Array frame is certified to AS1170.2 for installation Location. Array frame is installed to manufacturer’s specifications. No galvanically dissimilar metals are in contact with the array frames or supports. Roof penetrations are suitably sealed and Weatherproofed. PV wiring losses are less than 3% at the maximum Current output of the array. Where PV array comprises multiple strings – string protection has been provided. Wiring is protected from mechanical damage and is appropriately supported. Weatherproof PV array isolator mounted adjacent to the array. (Rating:…………………………..Vdc, …………….Adc) ELV, LV DC and AC INSTALLATION All low voltage wiring has been installed by a licensed electrical tradesperson. CONTINUITY CHECK Continuity of all string, sub-array and array cables. Continuity of all earth connections. (including module frame) Continuity of all ELV Battery cables. All wiring has been tested and approved by qualified electrical tradesperson. BATTERY INSTALLATION DETAILS Number of batteries in a series string. Number of battery strings in parallel. Rated Battery Voltage. Rated Battery Current @ C100 Manufacturers’ Float Voltage. (V/Cell) DC Battery Cable size. (Calculated) Designed maximum Depth of Discharge. (%) Days of Autonomy. BATTERY ENCLOSURE Shed Room Ventilation size. (Calculated) Box Batteries are isolated from the floor. Distance from System Components. YES SYSTEM TEST WARNING: IF A STRING IS REVERSED AND CONNECTED TO OTHERS, FIRE MAY RESULT. IF POLARITY IS REVERSED AT THE INVERTER, DAMAGE TO THE INVERTER MAY OCCUR. IF POLARITY IS REVERSED AT THE BATTERY PROTECTIVE DEVICE OR INVERTER, ARCING AT THE PROTECTION DEVICE & DAMAGE TO THE INVERTER MAY OCCUR. Time test taken: ……………….. Weather conditions: ……………………………………………………………….. String 1 - At String Protective device, Short Circuit Current Voltage Test Results Operating Current Polarity Checked OR, V A A OR, V A A OR, V A A OR, V A A PV Array at PV Array Rooftop Isolator. (When string protective devices are used) V A A Sub-arrays where required. V A A At PV Array Rooftop Isolator. String 2 - At String Protective device, At PV Array Rooftop Isolator. String 3 - At String Protective device, At PV Array Rooftop Isolator. String 4 - At String Protective device, At PV Array Rooftop Isolator. Battery Cell Voltage. (Voc) Battery System Voltage. (Voc) INSULATION RESISTANCE MEASUREMENTS (Refer AS/NZS5033:2012 Appendix-D Table “D2”) Array POSITVE to EARTH. MΩ Array NEGATIVE to EARTH. MΩ CONTINUITY CHECK Continuity of all string, sub-array and array cables Ω Continuity of all earth connections (including module frame) Ω Document D-06 Example Wiring Diagram Document D-07 System Performance Estimate Under the CEC design guidelines the designer has many responsibilities and one of the main responsibilities is in providing: “A site specific full system design including all shading issues, orientation and tilt, along with the system’s site specific energy yield, including average daily performance estimate in kWh for each month of solar generation.” And “Ensure array configuration is compatible with the inverter specification.” Sources: You can use the detailed formulae available from the CEC design guidelines to help with these design calculations. Alternatively you may use the free online CEC Performance Calculator, available to all currently accredited designers/installers, using your installer login at www.solaraccreditation.com.au There are many commercial tools available to assist in calculating energy yield, for example PV-GC, SunEye, PVSyst, Solar Pathfinder, PV Watts, SolarPlus, etc. Some of these make an allowance for shading. Please note that many inverter manufacturers’ software will not provide sufficient detail in terms of monthly generation figures. (Install Only Applicants: Please obtain the above information from your system designer) Example of acceptable data from CEC Performance Estimator: Document D-08 Engineering Certificate for the PV mounting frame system. Please enclose a copy of the Engineering Certificate for the PV frame mounting system that you have used in this installation. This will be available from your frame manufacturer or supplier. Please note: - An installation manual is not an engineering certificate. - A TUV Certificate is not an engineering certificate. As a Minimum the Engineering Certificate should include: Engineering Company Name & Business details. Brand / Model number of the frame tested. Identification of Geographical region of testing. Reference Standards associated with the certificate (AS/NZS 1170.2) Name of Engineer and ID number who certified the equipment. Document D-09 Mounting System- Installation Details Please insert details for this installation below: Wind Region (See Map) Actual Maximum distance between your brackets /rail feet Document D-10 System Load Design A system performance load design must be included as part of the design documentation in acordance with AS/NZS4509.2 Section 5 Appendix A (This DOES NOT preclude the use of commercial design software or purpose-built spreadsheets) EXAMPLE CASE STUDY-EXAMPLE OF PHOTOGRAPHS REQUIRED Installation Photos - Examples P-02 Solar Array on Roof P-03 Roof fixing brackets securing rails in position /fixing of brackets to roof. P-04 Solar Module Earthing device if required (How is panel earthed to rail) P-05 Solar Rail Earthing device if required (How is earth cable secured –Note Gal Spray) Anodized skin of solar panels & rail must be pierced with Earthing Device P-06 Rail Joiner / Splice kit (Showing continuity between segments) Anodized skin of rail must be pierced with Earthing Device Ano P-07 Rooftop Isolator & string Fuses if required. P-08 Roof Penetration (Main Cable entry point from array) P-09 DC Cable identification, mechanical protection & reticulation P-10 Under-Module cabling / cables secured from damage. On the Ground P-11 Inverter & Isolators installed (Broad View) P-12 Close up- DC isolator Internal View (showing wiring) P-13 Main Switchboard / Meter Panel & Upstream Switchboard Labeling (1, 2 or more pictures to cover all below) P-14 Close up of batteries (showing link connections) P-15 Close up of battery enclosure (showing ventilation) BATTERY ENCLOSURE EXAMPLES ONLY Battery Room Battery/Equipment Room Note: 1. 2. This is a dedicated Battery and/or Battery/Equipment room that is secured to prevent unauthorized entry The equipment room is ventilated to the outside as per AS4086.2 Note: The battery enclosure is ventilated to the outside as per AS4086.2 Examples of required labels L-001 - On switchboard to which inverter is directly connected L-002 - is permanently fixed at the main switch L-003 - is permanently fixed at the solar main switch L-004 - If the solar system is connected to a distribution board then the following sign is located on main switchboard and all intermediate distribution boards L-005 - Where the inverter is not adjacent to the main switchboard, location information is provided L-006 - Is permanently fixed on array junction boxes (black on yellow) L-007 - Fire emergency information is permanently fixed to the main switchboard and/or meter box (if not installed together) L-008 - PV DC isolation is clearly identified L-009 - Is placed adjacent to the inverter when multiple isolation/disconnection devices are used that are not ganged together L-010 - Exterior surface of wiring enclosures labelled ‘SOLAR DC’ SOLAR DC L-011 – Installation specific Shutdown Procedure. L-011a – Site plan layout Refer to AS4509.1 Section 2.3, 2.4 & 2.5 Example shown L-011 & L-011a L-012 – Electrolyte Burns & Danger Risk of Battery Explosion. Danger risk of battery explosion & Electrolyte Burns labeling placed externally on the battery enclosure or room L-012b - Example Electrolyte Burns labeling placed externally on the battery enclosure or room L-012a - Example Danger risk of battery explosion placed externally on the battery enclosure or room L-013 - Any other signage that may be required by local distributer. NO ENTRY AUTHORISED PERSONNEL ONLY This label should be placed externally on the battery enclosure or room L-014 – WARNING Uninterruptible Power Supply System L-015 – Main Battery Isolator This label should be placed on the Fuse Switch or DC Circuit Breaker. This label should be located on the main switchboard and all intermediate distribution boards L-016 – Earth Stake with Label L-017 - Required In Victoria on MSB This label should be located on the Earth Stake WARNING Main Electrical Earthing Conductor Do Not Disconnect Supporting Documentation & Helpful Links: Accreditation Installer Resources – http://www.solaraccreditation.com.au/installers/compliance-and-standards/standards.html Bureau of Meteorology - www.bom.gov.au Relevant Standards (NOTE: some aspects of these standards are relevant to grid-connected PV systems) - AS/NZS 3000 Wiring rules AS/NZS 1768 Lightning protection AS 3595 Energy management programs AS/NZS 4509.1 Stand-alone power Safety and Installation - AS/NZS 4509.2 Stand-alone power System Design - AS 4086.2 Secondary Batteries for use with Stand-alone Power Systems - AS/NZS 3008 Selection of cables AS/NZS 1170.2 Wind loads AS/NZS 5033:2012 AS/NZS 4777.1 Grid connection energy systems via inverters - AS/NZS 4509.3 Stand-alone power Installation and Maintenance Warning, This premise contains…. (Required In Victoria) THE FINAL CHECKLIST! HAVE YOU INCLUDED THE FOLLOWING? 1 The Application form 2 Copy of your Electrical License 3 Copy of your Current Public Liability Insurance 4 Installer ID Photo 5 Testing & Commissioning Sheet 6 Wiring Diagram with equipment details 7 System Performance Estimate (Best/Worst Month) 8 Engineers Certificate for mounting frames 9 Details of your wind region & rail foot spacing 10 System Load Design 11 Installation Photographs Failure to supply any of the above will result in long delays processing your case as we await the missing information. Note: Clean Energy Council have a 5MB size limit on incoming e-mails so you may need to re-size pictures if you are e-mailing them.