USOO62O118OB1

(12) United States Patent (10) Patent No.: US 6,201,180 B1

Meyer et al. (45) Date of Patent: Mar. 13, 2001

(54) INTEGRATED PHOTOVOLTAIC SYSTEM 5,232,518 8/1993 Nath et al. ........................... 136/251
5,289.999 3/1994 Naujeck et al. ..................... 244/173
(75) Inventors: John F. Meyer, Eagle; David G. 5.406,936 4/1995 Hirai et al............ 126/623
Porter, East Troy; Daniel H. Zietlow, St.
2- as : E. Me - - - - - - - - - C- -tal.".
aClOOC al. ................. E:

Mytile Ristina Rege,

. . royer, both of East 1 roy, all o
5,589,006 * 12/1996 Itoyama et al. ......................... 363/131
5,592,074 * 1/1997 Takehara .....
136/248
(US) 5,677,833 10/1997 Bingley ... ... 363/71
5,701,067 * 12/1997 Kaji et al. ................................ 320/2
(73) Assignee: Omnion Power Engineering Corp., 5,747,967 * 5/1998 Muljaldi et al. . ... 326/39
East Troy, WI (US) 5,927,026 7/1999 Durham .............................. 52/173.3
(*) Notice: Subject to any disclaimer, the term of this * cited by examiner
patent is extended or adjusted under 35
U.S.C. 154(b) by 0 days. Primary Examiner Ellis Robinson
Assistant Examiner Michael C. Miggins
(74) Attorney, Agent, or Firm Andrus, Sceales, Starke &
(21) Appl. No.: 09/293,400 Sawall
(22) Filed: Apr. 16, 1999 (57) ABSTRACT
(51) Int. Cl. .......................... H01L 31/05; H01L 31/042 An integrated photovoltaic System includes a plurality of
(52) U.S. Cl. .......................... 136/244; 52/173.3; 126/623 individual photovoltaic modules that each convert Solar
(58) Field of Search ..................................... 136/244, 245, energy into DC power. Each of the photovoltaic modules is
136/246; 52/173.3; 126/621, 622, 623 coupled to a busway that combines the DC power generated
by each photovoltaic module into a DC power output. The
(56) References Cited connection between each photovoltaic module and the
U.S. PATENT DOCUMENTS
busway is environmentally
- 0
Sealed,s as is the electrical wiring
contained within the busway. The busway is coupled to a DC
4,217,633 8/1980 Evans, Jr. ............................... 363/27 to AC power inverter that provides a Supply of AC power.
4,233,085 11/1980 Rodericket al. . . . 136/244 The coupling between the busway and the power inverter is
4,283,106 8/1981 Bunnell ............. ... 339/125 environmentally protected, Such that the entire DC wiring
4,375,662 * 3/1983 Baker ................ -- --- - g for the photovoltaic System is environmentally Sealed and
4,636,931 * 1/1987 Takahashi et al. ----- the System functions as an "AC photovoltaic System' having
4,680,690 7/1987 Dickerson ......... -- --- - 363f43

4,980,574 12/1990 Cirrito ........... - - - - - - 33: an AC power output.

5,092,939 * 3/1992 Nath et al. ........ ... 136/251
5,125,608 * 6/1992 McMaster et al. - - - - - - - - - - - - - - - 248/163.1 27 Claims, 10 Drawing Sheets
U.S. Patent US 6,201,180 B1

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U.S. Patent Mar. 13, 2001 Sheet 3 of 10 US 6,201,180 B1
U.S. Patent Mar. 13, 2001 Sheet 4 of 10 US 6,201,180 B1

FIG. 4
U.S. Patent Mar. 13, 2001 Sheet 5 of 10 US 6,201,180 B1
U.S. Patent Mar. 13, 2001 Sheet 6 of 10 US 6,201,180 B1
U.S. Patent Mar. 13, 2001 Sheet 7 of 10 US 6,201,180 B1

89 90

Z %2 Z
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FIG. 11
3 44

44
90
94
48

FIG. 12
U.S. Patent Mar. 13, 2001 Sheet 8 of 10 US 6,201,180 B1
U.S. Patent Mar. 13, 2001 Sheet 9 of 10
U.S. Patent Mar. 13, 2001 Sheet 10 of 10 US 6,201,180 B1

68 2

Sea
106
 US 6,201,180 B1
1 2
INTEGRATED PHOTOVOLTAC SYSTEM panel does not have to deal with external DC wiring.
Although this type of “AC photovoltaic module” functions
BACKGROUND OF THE INVENTION well and avoids many of the above-identified problems,
The present invention generally relates to a photovoltaic incorporating a DC to AC power inverter into each indi
energy System. More Specifically, the present invention vidual photovoltaic panel greatly increases the cost of the
relates to a photovoltaic energy System that includes a individual panels as compared to conventional photovoltaic
plurality of photovoltaic modules coupled to a power panels that output DC power.
inverter by environmentally protected wiring within a It is therefore an object of the present invention to provide
busway Such that the photovoltaic System outputs AC power. a photovoltaic energy System that combines a plurality of
Conventional photovoltaic power Systems for use in resi individual photovoltaic modules and a single DC to AC
dential and Small commercial applications typically include power inverter into an environmentally protected assembly
a plurality of interconnected photovoltaic modules mounted that outputs a Supply of AC power. It is a further object of
on the roof of the residential or commercial building. The the invention to provide a photovoltaic System that incor
interconnected modules are often referred to an array. Each porates a busway that interconnects the plurality of indi
15 vidual photovoltaic modules and the power inverter in an
of the photovoltaic modules includes numerous photovoltaic
cells that convert Solar energy into DC power. Typically, the environmentally protected manner. It still a further object of
DC power generated by each of the modules is combined by the invention to provide a photovoltaic module in which the
conventional external wiring and fed to a remote DC to AC busway and the individual photovoltaic modules include
power inverter, such as the Series 2400 produced by Omnion mating plug members and receptacles that allow the indi
Power Engineering Corporation, East Troy, Wis., assignees vidual modules to be connected to the busway in an envi
of the present application. In this type of photovoltaic ronmentally sealed manner. It is still a further object of the
System, the external wiring carrying the DC power runs from invention to provide an DC to AC power inverter that is
the photovoltaic modules on the roof of the building down removably connected to the busway and environmentally
to the power inverter, which is mounted either internally or protected when attached to the busway, Such that the entire
externally to a wall of the building. In most photovoltaic 25 DC wiring for the photovoltaic System is concealed and
power Systems, the power inverter is positioned near the protected.
electrical power input to the building from a utility provider, In yet another object of the invention, the busway includes
since the AC power output of the power inverter is fed into multiple Segments that are each attached to or incorporated
the distribution panel for the building along with the utility within the frame member defining each individual photo
power Supply. voltaic module. It is still a further object of the invention to
Although this type of photovoltaic power System has provide a photovoltaic System in which the busway is
proved to be an effective way to Supplement the electrical formed from joined busway Segments that each include an
energy Supplied by the utility provider, the external DC end plug and an end receptacle that allows the busway
wiring running between the individual photovoltaic modules 35
Segments to be connected and environmentally Sealed.
and from the roof of the building down to the power inverter Various other features, objects and advantages of the
presents problems during installation of the photovoltaic invention will be made apparent from the following descrip
power System. Since DC wiring is Seldom installed in tion taken together with the drawings.
building projects other than photovoltaic Systems, electri SUMMARY OF THE INVENTION
cians more familiar with AC wiring codes and requirements 40
often have difficulty in knowing how to comply with all of The present invention is designed to eliminate or over
the Specific building code requirements that accompany the come the problems inherent in the conventional photovoltaic
proper installation of DC wiring. Thus, the installation of a power Systems described above. In accordance with the
photovoltaic power Systems having external DC wiring invention, a photovoltaic System comprises a plurality of
requires the electrician installing the System to expend a 45 individual photovoltaic modules that each convert Solar
Significant amount of time reviewing Seldom used building energy into DC power. The photovoltaic System includes
code requirements for DC wiring, which increases the cost environmentally protected electrical wiring that connects the
and time of the installation process. plurality of photovoltaic modules and provides a DC power
In addition to the problems caused by the DC wiring output. The electrical wiring and the individual connections
during the installation process, the National Electric Code, 50 between each photovoltaic module are environmentally pro
which is adopted by most local governments, imposes tected Such that the electrical wiring and the photovoltaic
additional requirements on photovoltaic power Systems that modules create a Sealed photovoltaic energy System.
include external DC wiring running from the photovoltaic The environmentally protected electrical wiring that pro
modules to the power inverter. The more Stringent require vides the DC power output is coupled to a DC to AC power
ments for external DC wiring mandated by the National 55 inverter. The DC to AC power inverter converts the DC
Electric Code result in higher System cost due to the addi power output into AC power that can be utilized in conven
tional components and Safety devices that must be included tional commercial and residential applications. In accor
in the photovoltaic power System. dance with the invention, the connection between the power
One way to alleviate the above-identified installation inverter and the electrical wiring providing the DC power
problems and to avoid the code requirements imposed on 60 output is environmentally protected, Such that the combina
photovoltaic Systems having external DC wiring is to incor tion of the photovoltaic modules, the electrical wiring, and
porate a DC to AC power inverter directly into each indi the power inverter forms a Single Sealed unit in which all of
vidual photovoltaic panel. In Such a System, Such as the the DC wiring is environmentally protected and a Single AC
Sunsine TM 300 manufactured by Ascension Technology, power output is generated.
Inc., Waltham, Mass., the DC power generated by each 65 In accordance with the present invention, a busway is
individual photovoltaic panel is converted into AC power provided that includes the electrical wiring that joins each of
within the panel itself, Such that an electrician installing the the photovoltaic modules. In one embodiment of the
 US 6,201,180 B1
3 4
invention, the busway includes a plurality of Spaced Sealed FIG. 9 is an enlarged perspective view of a portion of the
receptacles that receive corresponding Sealed plug members photovoltaic System shown in FIG. 3, illustrating a single
formed on each of the photovoltaic modules. The combina photovoltaic module, a Single busway Segment and a single
tion of the Sealed receptacles on the busway and the Sealed Structural Support Segment;
plug members on the photovoltaic modules allow the pho FIG. 10 is an enlarged partial Section View taken along
tovoltaic modules to be coupled to the busway and be line 10-10 of FIG. 9 illustrating the interconnection
environmentally protected. between a receptacle contained on the busway Segment and
The busway of the invention can include either a Single, a plug member formed on the photovoltaic module,
continuous member eXtending the entire length of the pho FIG. 11 is a partial section view taken along line 11-11
tovoltaic array between the plurality of modules, or can 1O
of FIG. 9;
include a plurality of individual busway Segments. In an FIG. 12 is a partial section view taken along line 12-12
embodiment utilizing the busway Segments, a single busway of FIG. 9;
Segment is associated with each of the photovoltaic modules FIG. 13 is a perspective view of an alternate embodiment
Such that each photovoltaic module is mounted to one of the of the busway and power inverter of the photovoltaic
busway Segments. The busway Segments are each joined to 15
System;
the busway Segments positioned adjacent thereto by con
ventional means, Such that the plurality of busway Segments FIG. 14 is an enlarged view taken along line 14-14 of
define the complete busway that is environmentally Sealed. FIG. 13 illustrating an alternate receptacle formed on the
In the preferred embodiment of the invention, each busway busway;
Segment includes a Sealed end plug and a Sealed receptacle FIG. 15 is a perspective view illustrating an alternate
formed on opposing ends that are received in the mating embodiment of the photovoltaic System of the present inven
element formed on the adjacent busway Segment. tion incorporating the busway into each of the photovoltaic
In accordance with one embodiment of the invention, the modules,
busway interconnecting the Series of photovoltaic panels can FIG. 16 is an enlarged partial perspective view taken
be a structural member such that the busway not only 25 along line 16-16 of FIG. 15 illustrating a receptacle formed
interconnects the modules but also forms at least a portion in the photovoltaic module,
of the mounting Structure for the plurality of photovoltaic FIG. 17 is an enlarged partial perspective view taken
modules. along line 17-17 of FIG. 15 illustrating an end plug formed
An important advantage of the photovoltaic System of the on one end of the photovoltaic module,
invention is that the power output from the System is AC. FIG. 18 is a perspective view illustrating the photovoltaic
Thus, conventional AC wiring, which is more commonly System of the present invention as mounted to a roof Surface;
used than DC wiring, runs from the photovoltaic System of FIG. 19 is a partial section view taken along line 19-19
the invention to the residential or commercial power distri of FIG. 18 illustrating the mounting of the busway to the
bution panel for the building. The entire DC wiring for the 35 roof Surface; and
photovoltaic System of the invention is Sealed and environ FIG. 20 is a partial section view taken along line 20-20
mentally protected, which makes field installation much illustrating the electrical connection passing through the roof
faster and easier than prior photovoltaic Systems. of the building to the power inverter.
BRIEF DESCRIPTION OF THE DRAWINGS DETAILED DESCRIPTION OF THE
40
The drawings illustrate the best mode presently contem INVENTION
plated of carrying out the invention. FIG. 1 illustrates a Supplemental electrical energy Supply
In the drawings: System 10 that converts Solar energy into AC power that can
FIG. 1 is a general Schematic diagram of a photovoltaic be used to Supplement the electrical power provided by an
energy System of the present invention including multiple 45 electrical utility provider, as represented by reference
photovoltaic modules and a single power inverter; numeral 12. The Supplemental electrical energy Supply
FIG. 2 is an alternate embodiment of the photovoltaic System 10 generally includes a photovoltaic energy System
System shown in FIG. 1 including detachable connectors 14 that outputs a Supply of AC power at an output line 16.
between the individual photovoltaic modules and a busway; The Supply of AC power supplied through the output line 16
FIG. 3 is a perspective view illustrating a first embodi 50 is coupled to a conventional distribution panel 18 for the
ment of the photovoltaic System of the present invention; electric power in a residential or commercial building. The
FIG. 4 is a perspective view of a busway, a Support distribution panel 18 is a conventional component included
member and a power inverter of the first embodiment of the in most modern buildings to distribute electrical power
invention; received from the utility provider 12 to the electrical devices
55 and wiring contained within the building. Typically, the
FIG. 5 is an enlarged partial perspective view taken along distribution panel 18 includes multiple circuit breakers or
line 5-5 of FIG. 4 illustrating the interconnection between fuses that direct the Supply of electrical power throughout
a pair of busway Segments, the building.
FIG. 6 is an enlarged partial perspective view of the area The photovoltaic System 14 converts Solar energy into a
identified by line 6-6 of FIG. 4 illustrating a sealed end cap 60 Supplemental AC power Supply that is coupled directly into
included on the terminal end of the busway; a distribution panel 18 by the output line 16. Although the
FIG. 7 is an enlarged partial perspective view taken along photovoltaic System 14 is described as being a Supplemental
line 7-7 of FIG. 5 illustrating an end plug included on one AC power Source, it should be understood that in periods of
end of the busway Segment; low electrical usage by the building, the entire electrical
FIG. 8 is an enlarged partial perspective view taken along 65 Supply for the building could be Supplied by the photovoltaic
line 8-8 of FIG. 5 illustrating a mating receptacle formed System 14 alone, without any electricity being drawn from
on an opposite end of the busway Segment; the utility provider 12. Additionally, if the building is
 US 6,201,180 B1
S 6
consuming very low amounts of electrical power, the pho well as the connection between the power inverter 26 and the
tovoltaic System 14 will actually Supply Surplus electrical busway 32, are environmentally Sealed to protect the inter
power back to the utility provider 12. In a contemplated nal electrical wiring carrying DC power within the busway
alternate embodiment not shown, a plurality of energy 32. In this manner, the entire photovoltaic System 14 is an
Storage devices, Such as batteries, can be connected to the environmentally Sealed unit that outputs AC power along the
photovoltaic System 14 to Store the Surplus electrical power output line 16. The busway 32 further includes an end cap
generated during periods of low demand. 38 connected to the busway by couplings 40 such that the
In the embodiment of the invention shown in FIG. 1, the end cap 38 seals the terminal end of the busway 32.
photovoltaic System 14 is an environmentally protected unit In a contemplated embodiment of the invention, a Status
that includes a plurality of individual photovoltaic modules line 41 can be coupled to the power inverter 26 to indicate
20 connected in series by electrical wiring 22. Each of the the current Status of the AC power being generated by the
individual photovoltaic modules 20 absorbs solar energy and power inverter 26. The status line 41 can transmit informa
converts the Solar energy into DC power. The Series, or tion from the power inverter 26 in many different manners,
array, of photovoltaic modules 20 are connected Such that an Such as via radio transmission, power line carrier variations
aggregate DC power output from the combination of the 15 in VARS or a dedicated communication link. The status of
photovoltaic modules 20 is present at input 24 to a power the power inverter 26 can be sent to a remote location or
inverter 26. The power inverter 26 is preferably a DC to AC displayed right at the photovoltaic System 14 Such that the
power inverter, such as the Series 2400 produced by Omnion operation of the photovoltaic System 14 can be readily
Power Engineering Corporation, East Troy, Wis., assignees monitored.
of the present application. The power inverter 26 converts Referring now to FIG. 3, thereshown is a physical
the DC power output from the plurality of photovoltaic embodiment of the photovoltaic system 14 of the present
modules 20 into an AC power supply. As shown in the invention. The photovoltaic system 14 includes the photo
preferred embodiment of FIG. 1, the AC power from the voltaic modules 20 connected through the busway 32 to the
power inverter 26 passes through a ground fault interrupt 28 power inverter 26. In the embodiment of the invention
before the AC power is distributed out of the photovoltaic 25
shown in FIG. 3, four individual photovoltaic modules 20
system 14 on the output line 16. The ground fault interrupt are coupled to the busway 32, although additional photo
28 can either be internally constructed within the power voltaic modules 20 could be added or one or more of the
inverter 26, or can be a separate component coupled to the photovoltaic modules 20 shown in FIG. 3 could be removed.
power inverter 26. In the preferred embodiment of the invention, the power
In the embodiment of the invention shown in FIG. 1, each inverter 26 is Selected Such that it can accommodate varying
of the photovoltaic modules 20 is hardwired to the adjacent numbers of photovoltaic modules 20 without being replaced.
photovoltaic module 20 by the electrical wiring 22. The Each of the photovoltaic modules 20 is a generally
series of photovoltaic modules 20 are hardwire connected to rectangular member that includes a plurality of connected
the power inverter 26 by the main power line 30. Since each 35 individual photovoltaic cells (not shown) that each convert
of the photovoltaic modules 20 outputs DC power, the Solar energy into DC power that is output from each indi
electrical wiring 22 between the photovoltaic modules and vidual photovoltaic panel 20. In the embodiment of the
the main power line 30 carry DC power. In the embodiment invention shown, each module 20 is approximately 2 feet in
of the invention shown in FIG. 1, the entire electrical wiring width by 5 feet in length, although other Size modules are
carrying DC power is environmentally protected within the 40 contemplated. The photovoltaic modules 20 are Supported
photovoltaic System 14, Such that only AC power leaves the between the busway 32 and a support member 42. The
environmentally Sealed photovoltaic System 14 at the output Support member 42 is Spaced from the busway 32 and is
line 16. positioned generally parallel to the busway 32. The Spacing
Referring now to FIG. 2, thereshown is an alternate between the busway 32 and the support member 42 depends
embodiment of the photovoltaic system 14. In the embodi 45 on the length of each photovoltaic module 20, such that the
ment shown in FIG. 2, each of the photovoltaic modules 20 combination of the busway 32 and the Support member 42
is connected to a busway 32 by a coupling 34. The couplings provide the required Support for the plurality of photovoltaic
34 allow each of the individual photovoltaic modules 20 to modules 20 on a Support Surface, Such as the roof of a
be connected and disconnected from the busway 32. The building.
couplings 34 between the busway 32 and the photovoltaic 50 Referring now to FIG. 4, the busway 32 of the preferred
modules 20 allow the busway 32 to join a user-selected embodiment is constructed from a plurality of joined indi
number of photovoltaic modules 20 together within the vidual busway Segments 44. The number of busway Seg
photovoltaic system 14. ments 44 included in the busway 32 can be changed depend
In the embodiment of the invention shown in FIG. 2, each ing upon the number of photovoltaic modules 20 to be
of the photovoltaic modules 20 generates approximately 250 55 included in the photovoltaic System 14. Generally, each of
Watts, Such that the four modules 20 combine to form a the busway Segments 44 is slightly longer than the width of
nominal 1 kW photovoltaic system 14. If fewer modules 20 each individual photovoltaic module 20, Such that a single
are used, the System 14 would generate less power. busway Segment 44 is associated with each photovoltaic
In addition to the couplings 34 between the photovoltaic module 20 and provides the required spacing between
modules 20 and the busway 32, a coupling 36 is positioned 60 adjacent modules, as shown in FIG. 3.
between the busway 32 and the power inverter 26. The Referring now to FIG. 6, each of the busway segments 44
coupling 36 allows the busway 32 to be separate from the generally includes an outer shell 45 that defines a hollow,
power inverter 26 and Subsequently connected to the power internal wireway 46 that extends through the entire length of
inverter 26 when desired. In the embodiment of the inven the busway segment 44. Specifically, the outer shell 45 of the
tion shown in FIG. 2, each of the couplings 34 and 36 65 present invention includes an upper wall 47, a lower wall 48
include a Sealing arrangement Such that the connections and a pair of spaced sidewalls 49. The wireway 46 defined
between the photovoltaic modules 20 and the busway 32, as by the outer shell 45 extends the entire length of the busway
 US 6,201,180 B1
7 8
Segment 44 and contains the electrical wiring within the Shown in FIG. 10 is the preferred embodiment of the
busway segment 44. In the preferred embodiment of the coupling 34 between the photovoltaic module 20 and the
invention, the outer shell 45 is formed from an electrically busway segment 44. A pair of electrical wires 68 contained
conductive material, Such as extruded aluminum. However, within the wireway 46 defined by the outer shell 45 of the
it is contemplated by the inventors that alternate materials busway Segment 44 pass through an opening 70 formed in
could be used to form the outer shell 45 while operating the upper wall 47 of the busway segment 44. Each of the
within the Scope of the present invention. For example, the wires 68 terminate with a pair of spaced metal plates 74
outer shell 45 could be formed from electrically non contained within a receptacle 76 attached to the upper wall
conductive materials. Such as molded plastic, nylon, PVC or 47 of the outer shell 45 by a pair of connectors 78. The
other equivalent materials. receptacle 76 is a generally circular member having a
As can be seen in FIG. 6, end cap 38 fits within the plurality of resilient O-rings 80 formed around its outer
terminal end of the busway 32 and seals off the hollow, circumference.
internal wireway 46 formed within the busway segment 44 The O-rings 80 Surrounding the receptacle 76 engage the
to environmentally protect the electrical wiring contained internal Surface of a mating plug member 82 Secured to the
within the wireway 46. The end cap 38 preferably is formed 15 bottom wall 84 of the photovoltaic module 20. The interac
from a resilient, slightly deformable material that engages tion between the O-rings 80 contained on the receptacle 76
the inner walls of the busway segment 44 to seal the and the inner wall of the plug member 82 provide an
wireway formed therein. environmentally Sealed coupling between the busway Seg
Referring now to FIGS. 7 and 8, each of the busway ment 44 and the photovoltaic module 20.
segments includes an end plug 50 formed on its first end 51 Internal wires 86 contained within the photovoltaic mod
and a mating receptacle 52 formed on its Second end 54. ule 20 that supply the DC power from the photovoltaic
Since each of the busway Segments 44 includes both an end module 20 each terminate in a single metal plate 88. Each of
plug 50 and a mating receptacle 52, each of the busway the metal plates 88 are received between a pair of the spaced
Segments 44 can be coupled to an adjacent busway Segment 25
metal plates 74 on the receptacle 76 to provide the electrical
44 to complete the Series electrified connection and create connection between the electrical wires 68 in the busway
the busway 32 having the desired length. segment 44 and the electrical wires 86 within the photovol
The end plug 50 formed on the first end 51 of the busway taic module 20.
segment 44 includes an outer wall 56 sized to frictionally As can be understood in FIG. 10, the photovoltaic module
engage the inner walls of the wireway 46 defined by the 20 can be installed on the busway segment 44 by simply
outer shell 45 of the busway segment 44. The outer wall 56 aligning the receptacle 76 on the busway Segment 44 with
Surrounds a pair of prongS 58 that are each coupled to the the plug member 82 attached to the top wall 84 of the
electrical wiring passing through the open wireway 46 photovoltaic module 20. Once aligned, the plug member 82
within the busway segment 44. The prongs 58 are Sur is pushed downward into the receptacle 76 Such that the
rounded by a resilient circular outer sleeve 60. 35 O-rings 80 provide an environmentally sealed enclosure for
The second end 54 of each busway segment 44 includes the electrical wiring extending between the busway Segment
the receptacle 52 having an outer wall 61 that frictionally 44 and the photovoltaic module 20. Since the connections
engages the inner walls of the wireway 46 and is recessed between adjacent busway Segments 44 are also environmen
from the second end 54 of the busway segment 44. When tally sealed, the entire DC wiring contained in the busway 32
adjacent busway Segments 44 are joined, the outer wall 56 40 and the plurality of photovoltaic modules 20 is environmen
of the end plug 50 contacts the recessed outer wall 61 of the tally protected Such that no external DC wiring needs to be
receptacle 52, while the prongs 58 are received within handled during the installation of the photovoltaic modules
mating slots 62 formed in the receptacle 52. Each of the slots 2O.
62 is surrounded by a circular wall 64 that is received within Referring now to FIG. 11, bottom wall 89 of the photo
the circular sleeve 60 surrounding the prongs 58. The 45 voltaic module 20 is coupled to the upper wall 47 of the
circular wall 64 includes increasing diameter Segments busway segment 44 by a pair of connectors 90. In the
formed on its outer circumference. The interaction between preferred embodiment of the invention, the connectors 90
the increasing outer diameter of the circular wall 64 and the are conventional rivets. In addition, a similar connector 90
resilient circular outer sleeve 60 environmentally seals the is used to secure the bottom wall 48 of the busway segment
interconnection between the electrical wiring within each of 50 44 to a support surface 94, as shown in FIG. 12, such as the
the busway Segments 44. roof of a building or other similar Structure.
Referring back to FIG. 4, the support member 42 prefer Although not shown in the Figures, the power inverter 26
ably is also formed from individual Support Segments 66, includes a plug similar to the end plug 50 contained on the
each of which has a length corresponding to the length of first end 51 of the busway segment 44, such that the power
each busway Segment 44 Such that the same number of 55 inverter 26 can be received in the receptacle 52 contained on
Support Segments 66 and busway Segments 44 are required the second end 54 of one of the busway segments 44, as
for the mounting of the plurality of photovoltaic modules 20. shown in FIGS. 7-8. Since the plug 50 contained on the
Referring now to FIG. 9, each of the individual photo power inverter 26 is received within the receptacle 52
voltaic modules 20 are electrically connected to the electri formed on the second end 54 of the busway segment 44, the
cal wiring contained within the busway Segments 44 by a 60 interconnection between the DC power contained within the
coupling 34 that provides an environmentally Sealed junc busway 32 and the internal components of the power
tion between the wiring contained within the photovoltaic inverter 26 is environmentally Sealed and protected.
modules 20 that carries the DC power from the module 20 Alternatively, the power inverter 26 could be integrally
and the internal wiring contained within the busway Segment formed with one of the busway segments 44 and thus
44. The coupling 34 allows the photovoltaic panel 20 to be 65 completely Sealed. AS discussed, the power inverter 26
attached to the busway Segment 44 and the wiring passing converts the DC power from the plurality of photovoltaic
therebetween be environmentally protected. modules 20 into a Single AC power output.
 US 6,201,180 B1
10
Although the present invention has thus far been defined of support members 108 that secure the Support segment 66
as including the busway 32 defined by a plurality of busway to the roof 106. Once both the busway segment 44 and the
Segments 44, an alternate embodiment of the busway 32 is support segment 66 are attached to the roof 106, the pho
shown in FIG. 13. In this embodiment, a sealed flexible tovoltaic module 20 can be mounted to the busway segment
conduit 96 is connected to the power inverter 26 and 44 in the manner previously discussed.
includes numerous Spaced T-connectorS 98 Spaced along its Referring now to FIG. 20, the power inverter 26 includes
length. Each of the T-connectors 98 receives the wires 86 an outer enclosure 114 that includes a Sealed plug-in con
from one of the photovoltaic modules 20 such that the nector 116 extending from bottom wall 118 of the outer
plurality of modules 20 would be connected by the flexible enclosure 114. The plug-in connector receives a mating
conduit 96. Like the plurality of individual busway segments
44, the flexible conduit 96 environmentally seals and pro connector 119 that extends through the roof 106. A flashing
tects the DC wiring passing through the flexible conduit. 120 surrounds the plug-in connector 119 to seal the opening
in the roof. An electrical conduit 122 extends from the
Additionally, the flexible conduit 96 and the T-connectors 98
provide Sealed couplings between the busway 32 and the plug-in connector 119 to the distribution panel 18 (FIG. 1)
individual photovoltaic modules 20. In the embodiment contained within the building. The electrical conduit 122 is
15 coupled to the power inverter 26 through the combination of
shown in FIG. 13, however, the busway 32 does not support the plug-in connectors 116 and 119. Since the output of the
the photovoltaic modules 20 but instead would be used in power inverter 26 is AC, the conduit 122 carries only AC
combination with a separate Support Structure.
Referring now to FIGS. 15-17, thereshown is another power which can be easily handled by licensed electricians.
embodiment of the busway 32 interconnecting the photo It is important to understand that a primary feature of the
voltaic modules 20. In the embodiment shown in FIGS. present invention is the environmentally protected connec
15-17, the busway 32 is formed integrally in one of the tions between the individual photovoltaic modules 20, the
edges of the photovoltaic module 20. As can best be seen in busway 32 and the power inverter 26, such that the only
FIGS. 16 and 17, the busway 32 is joined to the edge of the exposed electrical wiring in the photovoltaic System 14 is
photovoltaic module 20 and is defined by an outer wall 100. 25
the AC power output at line 16. Additionally, the photovol
The outer wall 100 defines a generally hollow open wireway taic System 14 of the invention is modular, Such that addi
that contains the electrical wiring that carries the DC power tional busway Segments 44 and photovoltaic modules 20 can
from the photovoltaic module 20. Each photovoltaic module Simply be plugged in to increase the power output of the
20 includes a first end 102 that includes the end plug 50 system 14. When modifying the photovoltaic system 14 in
having the pair of spaced prongs 58. Second end 104 of each this manner, the DC wiring is completely contained Such that
photovoltaic module 20 includes the receptacle 52 having Special code requests and installation Steps that result from
the increasing diameter circular wall 64 Surrounding the pair exposed DC wiring do not need to be taken. Since only AC
of slots 62. power is accessible from the photovoltaic System 14, there
AS previously discussed in the description of the indi is no need to worry or deal with special building code
vidual busway segments 44 shown in FIGS. 7 and 8, the end 35
requirements associated with DC wiring, as was the case in
plug 50 is received within the receptacle 52 such that the previously available photovoltaic Systems.
circular wall 64 forms an environmentally protected Seal Various alternatives and embodiments are contemplated
with the circular outer sleeve 60 to protect the DC wiring as being within the Scope of the following claims particu
passing between adjacent modules 20. The primary differ larly pointing out and distinctly claiming the Subject matter
ence between the embodiment shown in FIGS. 15-17 and 40 regarded as the invention.
the embodiment including the individual busway Segment What is claimed is:
44 is that the busway 32 in the embodiment shown in FIGS. 1. A photovoltaic System for providing a Source of AC
15-17 does not provide structural support for the individual power, the photovoltaic System comprising:
photovoltaic modules 20. Instead, the busway 32 is formed a plurality of individual photovoltaic modules for con
integrally with the photovoltaic modules 20 Such that the 45 Verting Solar energy into DC power;
modules can be simply coupled together and the DC wiring an enclosed busway coupled to each of the plurality of
passing between adjacent modules is environmentally pro photovoltaic modules to combine the DC power from
tected. each module and provide a DC power output, wherein
Although not shown in the Figures, it is contemplated that each photovoltaic module includes a Sealed plug mem
the busway 32, shown in FIGS. 3-13 as being formed from 50 ber that is received in a mating Sealed receptacle
a plurality of busway Segments 44, could be constructed formed in the busway to provide an environmentally
from a single member having the Same or different croSS protected electrical coupling between the photovoltaic
Sectional shape as the busway Segments 44. Although a modules and the busway; and
Single piece busway 32 is contemplated, transporting Such a a power inverter connected to the busway for converting
busway would be more difficult due to the length of the 55 the DC power output from the plurality of photovoltaic
busway, Such that multiple joined busway Segments 44 are modules to AC power for output from the photovoltaic
contemplated as being the preferred embodiment. System, wherein the busway provides an environmen
Referring now to FIGS. 18-20, thereshown is a represen tally protected connection between the electrical wiring
tation of the photovoltaic System 14 as mounted to a roof and the power inverter.
106. As shown in FIG. 18, the power inverter 26 is posi 60 2. The photovoltaic system of claim 1 wherein the busway
tioned on the roof 106 and connected to one of the busway includes an Outer shell defining an internal wireway sized to
segments 44. As shown in FIG. 19, the lower wall 48 of the contain the electrical wiring interconnecting the plurality of
busway segment 44 is connected to a support member 108 photovoltaic modules and the power inverter, wherein the
by a pair of connectors 110, Such as conventional rivets. outer shell environmentally protects the electrical wiring
Support members 108 space the busway segment 44 above 65 contained within the internal wireway.
the roof 106 and are each connected to the roof 106 by a pair 3. The photovoltaic system of claim 2 wherein the outer
of ScrewS 112. The Support Segment 66 also includes a pair shell is formed from an electrically insulating material.
 US 6,201,180 B1
11 12
4. The photovoltaic system of claim 1 wherein the busway a power inverter directly coupled to the busway for
is a single, continuous member extending between the converting the DC power output to AC power for
plurality of photovoltaic modules. output from the photovoltaic System, wherein the cou
5. The photovoltaic system of claim 1 wherein the busway plings between the busway and the plurality of photo
includes a plurality of individual busway Segments, wherein Voltaic modules and the coupling between the busway
one of the busway Segments is coupled to each photovoltaic and the power inverter are each environmentally
module and the plurality of busway Segments are joined and Sealed.
environmentally Sealed to define the busway. 14. The photovoltaic system of claim 13 wherein the
6. The photovoltaic system of claim 5 wherein the busway power inverter includes a Sealed plug that is received in a
Segments telescopingly engage the buSWay Segments posi mating Sealed receptacle formed in the busway Such that the
tioned adjacent thereto. power inverter is removably coupled to the busway and the
7. The photovoltaic system of claim 5 wherein each of the connection between the power inverter and the busway is
busway Segments includes an end plug and a receptacle Such environmentally Sealed.
that the end plugs and receptacles of adjacent busway 15. The photovoltaic system of claim 13 wherein each
Segments engage each other to form environmentally pro photovoltaic module includes a frame member that Supports
15
tected connections between the electrical wiring within the a plurality of individual photovoltaic cells, wherein the
busway Segments.
8. The photovoltaic system of claim 1 further comprising frame member includes an internal wireway, Such that the
a plurality of Support members coupled to the busway for internal wireways of adjacent photovoltaic modules are
attaching the busway and the photovoltaic modules to a joined to define the busway between the individual photo
Support Surface. Voltaic modules.
9. The photovoltaic system of claim 1 further comprising 16. The photovoltaic system of claim 15 wherein each
a status transmission member coupled to the power inverter frame member includes an end plug and a receptacle, Such
for communicating the Status of the power inverter to a that the end plugs and receptacles of adjacent frame mem
location remote from the photovoltaic System. bers engage each other to form environmentally protected
10. The photovoltaic system of claim 1 further comprising 25 junctions between the photovoltaic modules.
a ground fault detector coupled to the AC power output of 17. The photovoltaic system of claim 13 wherein the
the power inverter. busway includes an Outer shell and electrical wiring con
11. The photovoltaic system of claim 1 further comprising tained within a wireway defined by the outer shell, wherein
a plurality of DC power Storage members coupled between the outer shell environmentally protects the electrical wiring
the plurality of photovoltaic modules and the power inverter contained within the wireway.
for storing a portion of the DC power output from the 18. The photovoltaic system of claim 17 wherein the
plurality of photovoltaic modules prior to conversion to AC busway includes a plurality of Supports attached to the outer
power. shell of the busway such that the busway and plurality of
12. A photovoltaic system for providing a source of AC Supports hold the photovoltaic System in place along a
power, the photovoltaic System comprising: 35 Support Structure.
a plurality of individual photovoltaic modules for con 19. A device for interconnecting a plurality of individual
Verting Solar energy into DC power; photovoltaic modules and providing a Source of AC power,
an enclosed busway coupled to each of the plurality of each module having a plug member that Supplies DC power
photovoltaic modules to combine the DC power from from the photovoltaic module, the device comprising:
each photovoltaic module to provide a DC power 40 an enclosed busway including environmentally protected
output, the busway including electrical wiring inter electrical wiring, the busway having a plurality of
connecting the photovoltaic modules and providing an Spaced Sealed receptacles that each receive the plug
environmentally protected connection between the member on one of the photovoltaic modules to connect
electrical wiring and each of the photovoltaic modules, the photovoltaic module to the electrical wiring within
and 45 the busway, Such that the electrical wiring within the
a power inverter coupled to the busway for converting the busway combines the DC power from the plurality of
DC power output from the plurality of photovoltaic photovoltaic modules and provides a DC power output,
modules to AC power for output from the photovoltaic wherein the connection between the busway and each
System, the power inverter including a Sealed plug that of the photovoltaic panels is environmentally Sealed;
is received in a mating Sealed receptacle formed in the 50 and
busway, Such that the power inverter is removably a power inverter coupled to the busway for converting the
coupled to the busway and the connection between the DC power output to AC power, the coupling between
power inverter and the busway is environmentally the power inverter and the busway being environmen
Sealed by the interaction between the Sealed plug and tally sealed such that the DC power is concealed within
the Sealed receptacle. 55 the device and the device provides a Source of AC
13. A photovoltaic System for converting Solar energy into power.
a Source of AC power, the System comprising: 20. The device of claim 19 wherein the busway includes
a plurality of individual photovoltaic modules for con an outer shell defining an internal wireway sized to contain
Verting Solar energy into DC power, each photovoltaic the electrical wiring that interconnects the plurality of pho
module including a Sealed plug member; 60 tovoltaic modules and the power inverter, wherein the outer
an environmentally Sealed busway having a plurality of shell environmentally protects the electrical wiring con
Sealed receptacles, each Sealed receptacle receiving the tained within the internal wireway.
Sealed plug member of one of the photovoltaic modules 21. The device of claim 20 wherein the outer shell is
to couple the plurality of photovoltaic modules to the formed from an electrically insulating material.
busway such that the busway combines the DC power 65 22. The device of claim 20 wherein the outer shell
from each module and provides a DC power output; includes a plurality of Support members coupled the outer
and shell for attaching the busway to a Support Surface.
 US 6,201,180 B1
13 14
23. The device of claim 19 wherein the busway is a single, end plugs and receptacles of adjacent busway Segments
continuous member extending between the plurality of pho engage each other to form environmentally protected con
tovoltaic modules. nections between the electrical wiring within the busway
24. The device of claim 19 wherein the busway includes Segments.
a plurality of individual busway Segments, wherein each of 5 27. The device of claim 19 wherein the power inverter
the busway Segments is coupled to one of the photovoltaic includes a Sealed plug member that is received in a mating
modules and the plurality of busway Segments are joined Sealed receptacle formed in the busway, Such that the power
and environmentally Sealed to define the busway. inverter is removably coupled to the busway and the con
25. The device of claim 24 wherein the busway segments nection between the power inverter and the busway is
telescopingly engage the busway Segments positioned adja environmentally Sealed by the interaction between the Sealed
cent thereto. plug and the Sealed receptacle.
26. The device of claim 24 wherein each of the busway
Segments includes an end plug and a receptacle Such that the k k k k k