Commissioning

Example of a commissioning checklist.

Commissioning is the process of starting up a system for the first time in a methodical manner to ensure that it is built as it should be, that it is operating safely and that it is performing as it should be. All work should be completed on a system before the commissioning process begins - it is the final step. A commissioning process will involve physically inspecting equipment, programming equipment, and testing the performance of equipment. The commissioning process varies for every system as each system will vary in terms of components or design, but there are steps that are common to the process of commissioning any off-grid PV system.

The commissioning process is intended to identify any potential design or installation errors before the issues pose a safety risk to installers, end users or the equipment itself. The process must be done methodically with all steps performed regardless of whether you were directly involved in the installation of a certain component or task. Nobody intends to make mistakes, nonetheless they occur. Mentally checking off tasks in your mind during the installation process is not the same as performing a proper commissioning process at the end of an installation that follows a checklist.

If an issue arises during the commissioning process - an installation error is found, a component is not being having as it should be - the process should be stopped until the issue has been addressed. It may be necessary to troubleshoot the system to identify the issue. It is important to have the system plans and manuals for all of the equipment in order to diagnose and resolve issues.

Any component programming should be performed during the commissioning process. Charge controller programming and inverter programming are of particular importance. Following the installation manual that details setup and programming is very important as the settings vary between manufacturers and models. It will also be necessary to have the manual for the energy storage system on hand. Complex systems may have hundreds of different programmable parameters, but these are frequently left on default settings and only a few primary settings are changed. Programming plays a vital role in the functioning of a PV system and an improperly programmed PV system may function poorly or not at all - even if it was designed and installed perfectly.

The commissioning process should be performed in three different phases. All phases should be undertaken methodically with safety as the primary concern. Turning on and testing a system for the first time can present unknown hazards to the person performing the process.

Phase 1: Initial commissioning

1. Follow proper electrical safety. All work should be completed. Everyone in the area should be made aware that the commissioning process is going to begin, which means that the system is going to become energized.
3. Open (turn off) all overcurrent protection devices and disconnects to ensure that there is no connection between all power source and all other components in the system.
5. Ensure that all equipment - particularly the inverter - is turned off.
7. Perform a physical revision of the system as compared to the system design in the plans:

• Are all components the correct manufacturer and model? Are the power and voltage ratings correct?
• Is the system properly labeled?
• Are all system components connected to one another correctly?
• Is the grounding system built properly?
• Are all system connections made properly?

• Are all series and parallel connections performed correctly?
• Wiggle the wires for each connection to ensure that they are not loose.
• Are all wires the correct size?
• Are all wires protected and secured?

9. Energy storage system

• Measure and record the voltage of each battery. Are all of the measurements similar? Is the voltage of each battery within an appropriate range for the battery type?
• Measure the voltage for each parallel string of batteries? Are the voltages correct for the design?
• Measure the voltage of the final connection between the energy storage system and the charge controller. Is the voltage and polarity correct for the design?
• Measure the voltage of the final connection between the energy storage system and the inverter. Is the voltage and polarity correct for the design?
• If voltages and polarities are correct, connect the energy storage system to the rest of the system by closing the overcurrent protection devices and disconnects for the energy storage system.

10. Charge controller

• Check voltage at the overcurrent protection device/disconnect for the charge controller. Is the voltage and polarity correct for the design?
• If voltage and polarity is correct, close (turn on) all overcurrent protection devices/disconnects between the energy storage system and charge controller.
• Has the charge controller registered the voltage and turned on? If so, proceed with the process.

11. Inverter

• Check voltage at the overcurrent protection device/disconnect for the inverter. Is the voltage and polarity correct for the design?
• If voltage and polarity is correct, close (turn on) all overcurrent protection devices/disconnects between the energy storage system and charge controller.
• Turn on the inverter.

• Is it operating correctly? No errors?
• Is the inverter outputting the correct voltage? If so, proceed with the process.

Phase 2: Programming

1. Charge controller programming
3. Inverter programming

Phase 3: Final commissioning

1. PV source

• Check the voltage and polarity for each parallel string of PV modules. The value will vary based upon the conditions but should be within an appropriate range given the conditions.
• If voltages and polarities are correct, close (turn on) all overcurrent protection devices/disconnects between the PV source and the charge controller.
• Has the charge controller registered the voltage from the PV source? If so, proceed with the process.

3. Power distribution

• Check the voltage and polarity of any DC lighting circuits or DC circuits connected to the energy storage system. Is the voltage and polarity correct for the design?
• If the voltage and polarity are correct, close (turn on) all overcurrent protection devices/disconnects between the DC power source and the loads.
• Have the loads (lights and appliances) registered the voltage from the DC power source? If so, proceed with the process.
• Check the voltage of all AC circuits connected to the inverter. Is the voltage correct for the design?
• If the voltage is correct, close (turn on) all overcurrent protection devices/disconnects between the AC power source and the loads.
• Have the loads registered the voltage from the AC power source? If so, proceed with the process.

5. Documentation

• Make sure that the process has been documented as this information can be useful later on.
• Take photos of the system.
• Document any changes or variances from the original system plans.
• Make sure that anyone who will be using the system understands how to do so properly.
• Make sure that someone who will be using the system understands how to maintain and troubleshoot the system.
• Make sure that appropriate manuals and documentation remain with the system.