Patent ID: 12255581

DETAILED DESCRIPTION

Rapid shutdown devices, rapid shutdown device systems, and accompanying methods for utilizing rapid shutdown devices and systems are disclosed herein. The US National Electric Code (NEC) has required photovoltaic modules and systems to incorporate the capability to quickly de-energize any while installed on a residential roof to make it safer for firefighters or other service personnel to interact in the event of an emergency. Initially, the NEC required array-level shutdown capabilities, however, the NEC has progressed to require module-level shutdown. Recent updates, for example, have effectively required a rapid shutdown device to be installed every 80V in a photovoltaic string of photovoltaic modules, which adds one extra electrical device for every photovoltaic module. Newer standards offer a physics-based approach to electrical safety instead of the previous 80V for every module approach. In certain embodiments, for example, the rapid shutdown devices and systems described herein enable the use of a rapid shutdown device at voltages higher than 30V and up to 600V. Additionally, the rapid shutdown device form-factor may be designed to meet the requirements for building-integrated photovoltaic systems. In certain embodiments, power line communication may be employed in combination with rapid shutdown devices for ease of installation and compatibility with various types of inverters utilized with photovoltaic modules and systems.

In certain embodiments, an exemplary rapid shutdown system is provided. In certain embodiments, the system may include a photovoltaic string that includes a plurality of photovoltaic modules. In certain embodiments, the photovoltaic string may be installed on a roof of a structure and one or more of the photovoltaic modules of the plurality of photovoltaic modules may include a first layer on a roof deck of the roof and a second layer having at least one photovoltaic cell. In certain embodiments, the second layer may be opposite to the roof deck. In certain embodiments, the system may include at least one electrical connection to a grid power supply associated with and/or providing power for the structure. In certain embodiments, the system may include at least one electronics housing installed on the roof of the structure, wherein the at least one electronics housing houses a rapid shutdown device in electrical communication between the photovoltaic string and the at least one electrical connection to the grid power supply. In certain embodiments, the rapid shutdown device includes a first power line and a second power line connected to the photovoltaic string and a high voltage switch on the first power line. In certain embodiments, the power lines may be structures used for electric power transmission between devices and/or componentry connected thereto. In certain embodiments, the power lines may be cables, wires, or other componentry including conductive material to facilitate the transfer and movement of electrical energy. In certain embodiments, the power lines may be covered by a non-conductive material, such as, but not limited to, plastic, rubber, and fluoropolymers, or any combination thereof. In certain embodiments, the voltage switch may be a solid state device that is configured to block positive voltage. In certain embodiments, for an ideal switch, the voltage may be zero and the current may flow through the circuit in either direction. In certain embodiments, the voltage switch may operate in two quadrants out of four of current-voltage (“i-v”) space. In certain embodiments, the voltage switches utilized in circuits described herein may include, but are not limited to, insulated-gate bipolar transistor (“IGBT”)-based switches, meta-oxide-semiconductor field-effect transistor (“MOSFET”)-based switches, other switches, or a combination thereof. In certain embodiments, the voltage switches (e.g., IGBT, MOSFET, etc.) may include silicon, silicon carbide, gallium nitride (GaN), other types of materials, or a combination thereof. In certain embodiments, the voltage switch may be a high voltage switch. In certain embodiments, the high voltage switch may be configured to disconnect the first power line while the high voltage switch is open. In certain embodiments, the high voltage switch may be configured to have a blocking voltage exceeding a string voltage that may be associated with power generated by the photovoltaic string. In certain embodiments, the blocking voltage may be a maximum voltage that the high voltage switch is capable of handling before causing damage to the switch. In certain embodiments, the rapid shutdown system may include a gate drive circuit configured to receive at least one electronic photovoltaic string status signal indicative of an operating status of the photovoltaic string, determine that the operating status of the photovoltaic string indicates a hazard based at least in part on the at least one electronic photovoltaic string status signal, and generate, based on the operating status of the photovoltaic string indicating the hazard, a high voltage switch command signal configured to cause the high voltage switch to open so as to disconnect the photovoltaic string from the at least one electrical connection to the grid power supply with the blocking voltage exceeding the string voltage.

In certain embodiments, a rapid shutdown device of the rapid shutdown device system may include an internal power supply configured to convert the string voltage for a photovoltaic string of photovoltaic string modules to a lower voltage needed for operation of the rapid shutdown device. For example, the internal power supply of the rapid shutdown device may receive 30V to 600V and convert it to 12V. In certain embodiments, the input range may be further narrowed down to 60V, 80V or any voltage higher than 30V and lower than 600V. In certain embodiments, the output voltage of the internal power supply of the rapid shutdown device may range from 1V to 24V or higher, depending on the implementation of the rapid shutdown device components. In certain embodiments, multiple power supplies may be implemented for different sub-circuits of the rapid shutdown device. In certain embodiments, the rapid shutdown device may be configured to handle string voltages as high as 1000V and above. In certain embodiments, the rapid shutdown device may include sub-circuits, such as a receiver circuit and a power circuit, as shown inFIG.19.

In certain embodiments, the receiver circuit may serve as the receiving end of the communication protocol between the rapid shutdown device and an inverter, which receives a stay-on or shutdown command and enables the photovoltaic string to generate power or stop generating power accordingly. In certain embodiments, the communication for the rapid shutdown device may be implemented through a hard wire and utilize protocols such as serial, controller area network (“CAN”), other protocols, custom logic codes, or analog voltage levels. In certain embodiments, wireless communication may be implemented by utilizing technologies, such as WiFi, Zigbee, Z-Wave, and the like. In certain embodiments, PLC may be used so that the data may be modulated through the power cables/lines connecting the inverter to the photovoltaic string. In embodiments utilizing the PLC for communication, that rapid shutdown device may include a filter to extract the signal sent through the power line connected to the rapid shutdown device and photovoltaic string. In certain embodiments, the rapid shutdown device may include a demodulator circuit that translates the PLC signal to a status command, which determines the configuration of the power circuit. In certain embodiments, a communication circuit may be also implemented for the rapid shutdown device by a bidirectional receiver/transmitter method. In this case, in addition to the primary function of the rapid shutdown device receiver circuit, other information may be transmitted back to the inverter, a user of the rapid shutdown device, or other devices.

In certain embodiments, the power circuit of the rapid shutdown device may include switching devices (e.g., voltage switches) such as relays or solid-state switches, including, but not limited to, metal-oxide-semiconductor field-effect transistors “(MOSFET”), insulated-gate bipolar transistors (“IGBT”), thyristors, or any combination thereof. In certain embodiments, solid-state devices may be utilized to further extend the life-cycle of the rapid shutdown device and enable smaller form-factors for the rapid shutdown device. In certain embodiments, the switches of the power circuit of the rapid shutdown device may be configured according to a status signal. In certain embodiments, an exemplary configuration of the power circuit includes two switches (e.g., switch1720(S2) and switch1721(S3) inFIG.17). In certain embodiments, when the switches are open, the photovoltaic string may be disconnected from the inverter. When the switches are closed, the photovoltaic string may be energized and connected to the inverter. In certain embodiments, instead of using two switches (i.e. a dipole configuration), only one switch may be employed in the rapid shutdown device power circuit (i.e., a monopole configuration). For example, either one of switches1820or1821may remain in the circuit and the other switch may be replaced with a conductive connection.

In certain embodiments, the rapid shutdown device may also include a switch and discharge resistor (e.g., switch1712(S1) and resistor1710(R1)) to de-energize any charge at the output of the inverter. In this case, discharge circuit switch may be closed when either or both of the switches of the power circuit are open, and the discharge circuit switch may be closed when power circuit switches are open. As a result, in certain embodiments, the status of the discharge circuit switch of the rapid shutdown device may be complementary to the status of the power circuit switches of the rapid shutdown device. In certain embodiments, the discharge circuit may be transformed to the inverter and not implemented within the rapid shutdown device.

In certain embodiments, there may be a power supply for powering both receiver and power circuits of the rapid shutdown device or separate power supplies may be utilized for the receiver and power circuits, with a separate power supply dedicated to each circuitry. In certain embodiments, the receiver circuit may be configured to output a command to the power circuit. In certain embodiments, the command may be changed by the rapid shutdown device according to the state of operation through a gate drive circuit.

In certain embodiments, the form-factor of the rapid shutdown device may be designed to match the functionality and aesthetics of a building-integrated photovoltaic system, in-roof solar system, or a combination thereof. An exemplary form-factor for the rapid shutdown device may be a flat design where the thickness of the device is substantially lower than the length and width of the rapid shutdown device, as shown inFIG.19. In certain embodiments, the form-factor of the rapid shutdown device may be optimized for a transition box or any enclosure that is mounted on the roof, in an enclosure in the attic, on the wall adjacent to the photovoltaic string, or any combination thereof. Another exemplary form-factor for the rapid shutdown device may be a slim design where the length of the rapid shutdown device is longer than the width and length of the rapid shutdown device, as shown inFIG.20. Such a design may be intended to fit in the wire-channels, wireways, wire ducts, or any combination thereof.

In certain embodiments, the electrical ratings of the rapid shutdown device may be configured to accommodate the photovoltaic string connected to the rapid shutdown device. In certain embodiments, the input current rating may be determined by the photovoltaic module and substring configurations. In certain embodiments, 6 A to 10 A ratings may accommodate modules with half-cut cells in series. In certain embodiments, 12 A to 20 A may accommodate a single string of full cell modules in series or two substrings of half cut cells in parallel.

In certain embodiments, the photovoltaic string includes photovoltaic modules with low leakage current below 2 mA, which is hazard level 0. In certain embodiments, the photovoltaic string of photovoltaic modules is gathered through interconnections (e.g., series and parallel) in a manner that the overall voltage remains below 1000V. In certain embodiments, the photovoltaic modules may not have any metal frames and all the components may be insulated such that no metal part is exposed, and no ground wiring is run through the photovoltaic string of modules. In certain embodiments, the photovoltaic modules may be directly attached to the surface below using fasteners (e.g., such as via nails, screws, and other fastening mechanisms) such that the fasteners are covered by other non-conductive modules or roofing materials. In certain embodiments, surface underneath may not be metal, but may be a wooden deck, or other roofing material such as underlayments or shingles.

In certain embodiments, the photovoltaic string of photovoltaic modules is connected to a rapid shutdown device, such as via a power line or wires. In certain embodiments, the rapid shutdown device may include one or more disconnecting switches, a circuits or other componentry to send stay on and/or turn off commands, as well as an enclosure (e.g., a housing) to be installed within a certain distance (e.g., 1 foot) of the string secured to the roof (e.g., 3 feet if the enclosure is installed in the attic). In certain embodiments, the disconnect switch may be implemented by utilizing electromechanical or solid-state relays or solid-state power electronics switches such as Power MOSFETs, IGBTs, thyristors, and IGCTs. In certain embodiments, the communication circuit may include hard-wired circuitry, such as those used for lighting applications. In certain embodiments, single, two, three or four-wire communication buses may be utilized. In certain embodiments, wireless communication technologies, such as Wi-Fi and Zigbee may also be utilized with the rapid shutdown device. In certain embodiments, the power line communication may be utilized with the rapid shutdown device, which may use photovoltaic wires that interconnect a grid-connected inverter to the photovoltaic string. As indicated above, the rapid shutdown system may also include a DC/AC inverter. In certain embodiments, the system may not require any specific inverter and may operate with any string as long as the proper transmitter is installed in the system to send the required signals to the rapid shutdown device of the system.

In certain embodiments, a configuration of the rapid shutdown system may encompass a configuration where the rapid shutdown device includes only one solid-state switch placed either at the beginning or end of the photovoltaic string. In certain embodiments, the switch may require a blocking voltage exceeding the string voltage for the photovoltaic string (e.g., the cumulative voltage of the modules in the string). In certain embodiments, the blocking voltage may be greater than or equal to 600V. In certain embodiments, the blocking voltage may be greater than 5% more than the string voltage, 10% more than the string voltage, or any percentage more than the string voltage. In certain embodiments, the current-carrying capacity may be greater than the photovoltaic string current. Moreover, the conductive losses may be dominant in the system. In certain embodiments, the allowable temperature rise may be determined by the difference between local ambient temperature and the maximum temperature allowed by adjacent material. GAF Energy has determined the local ambient temperature by running MST 21 testing for the product including the enclosure on the roof. The roof mounted enclosures and wire covers are introduced through other invention disclosures including transition box and roof attach components. In certain embodiments, roof-mounted enclosures and wire covers utilized with the rapid shutdown system may comprise non-metallic material. In certain embodiments, the wire insulation may be one of the limiting factors for temperature rise.

In certain embodiments, the disconnect switch may include a power supply for a gate drive circuit of the rapid shutdown device. In certain embodiments different switches may be driven at specific supply voltages ranging from 5V to above 20V. In certain embodiments, the photovoltaic string of photovoltaic modules may be directly connected to the rapid shutdown device and/or rapid shutdown device system. In certain embodiments, the photovoltaic string voltage may vary depending on the number of photovoltaic modules in the string and the configuration. For example, the voltage may vary from 50V to 600V. In certain embodiments, the power supply gate-drive circuit may reduce the voltage from this range to the required voltage for the gate drive circuit of the rapid shutdown device. In certain embodiments, different technologies for the power supply of the rapid shutdown device may include, but are not limited to, an isolated power supply with high frequency transformer, multi-stage, non-isolated DC-DC converters, charge pump circuits, or bootstrap circuits.

In certain embodiments, the command for controlling the switch may come through the communication circuit. Specifically, in certain embodiments, PLC serves an attractive technology because it does not require any additional wiring. In certain embodiments, the PLC componentry may utilize a receiver circuit including a filter and demodulator circuit. In certain embodiments, the circuitry may utilize a power supply ranging from 8V to 20V. In certain embodiments, power can be provided by a separated power supply or a similar power supply to the gate drive circuit if the voltages match. In certain embodiments, the receiver integrated circuit may be configured to demodulate the PLC communication and generates a command for the rapid shutdown device to either stay closed (on) or to be disconnected (off). In certain embodiments, after the rapid shutdown device is disconnected, the inverter voltage may be discharged either through the discharge circuit built-in to the inverter or a discharge circuit implemented in the rapid shutdown device itself. In certain embodiments, a way in which to implement the discharge circuit is to have a discharge switch that operates complementary with the rapid shutdown device switch. In certain embodiments, the discharge switch may establish a discharge path between the positive and negative terminals of the rapid shutdown device at the inverter side.

The rapid shutdown devices and systems according to the present disclosure provide a plurality of enhancements and optimizations to rapid shutdown technologies. For example, embodiments of the rapid shutdown devices and systems may utilize a monopole (i.e., a single switch on a single power line) to disconnect the photovoltaic string from a grid supply upon detection of a hazard. In certain embodiments, the photovoltaic modules utilized in the photovoltaic string may be low leakage current even damaged due to the structure and due to not having a metal frame or being grounded. In certain embodiments, there is no exposed metal in the rapid shutdown system and no grounding is required. In certain embodiments, the rapid shutdown devices are designed to fit the enclosures, such as those used for building-integrated photovoltaic systems.

Referring now also toFIGS.1-13, exemplary photovoltaic shingles, modules, and roofing systems that may be utilized with the rapid shutdown devices of the present disclosure are schematically illustrated. More specifically referring toFIGS.1A through2D, in certain embodiments, a roofing system5includes a plurality of photovoltaic shingles10, each of which includes a first layer12and a second layer14overlaying the first layer12. In certain embodiments, the first layer12and the second layer14may have direct contact with each other and the second layer14may be laid on top of at least a portion of the first layer12. In certain embodiments, the first layer12includes a head lap16. In certain embodiments, the second layer14includes at least one solar cell18. In certain embodiments, the at least one solar cell18includes a plurality of the solar cells18. In certain embodiments, at least one of the plurality of photovoltaic shingles10overlays at least the head lap16of another of the plurality of photovoltaic shingles10. Still referring toFIGS.1A through2D, in certain embodiments, the first layer12includes a first end20, a second end22opposite the first end20, a third end24extending from the first end20of to the second end22, and a fourth end26opposite the third end24and extending from the first end20to the second end22. In certain embodiments, the head lap16extends from the third end24to the fourth end26. In certain embodiments, the second layer14extends from the third end24of the first layer12to the fourth end26of the first layer12. In certain embodiments, the second layer14extends intermediate the third and fourth ends24,26of the first layer12. In certain embodiments, the second layer14is located proximate to the second end22of the first layer12.

In certain embodiments, the head lap16includes a first width W1and the second layer14includes a second width W2. In certain embodiments, the first width W1extends from the first end20of the first layer12to the first end28of the second layer14. In certain embodiments, the second width W2extends from the first end28of the second layer14to the second end30of the second layer14. In certain embodiments, the first width W1is greater than the second width W2. In certain embodiments, the second width W2is greater than the first width W1. In certain embodiments, the first width W1and the second width W2are equal to one another.

Still referring toFIGS.1A through2D, in certain embodiments, each of the plurality of photovoltaic shingles10includes a fold line36extending from the first end20of the first layer12to the second end22of the first layer12and intermediate the third and fourth ends24,26of the first layer12. In certain embodiments, the fold line36extends from and through the first end28of the second layer14to the second end30of the second layer14. In certain embodiments, the fold line36enables the photovoltaic shingle10to be folded in half for reduction of space in connection with the storage or transport of the photovoltaic shingle10. In certain embodiments, each of the plurality of photovoltaic shingles10includes a first section38extending from the third end24of the first layer12to the fold line36, and a second section40extending from the fourth end26of the first layer12to the fold line36. In certain embodiments, the first section38includes a first portion42of the head lap16and a first portion44of the second layer14, and the second section40includes a second portion46of the head lap16and a second portion48of the second layer14. In certain embodiments, the at least one solar cell18includes a first one50of the at least one solar cell18located in the first portion44of the second layer14and a second one52of the at least one solar cell18located in the second portion48of the second layer14. In certain embodiments, the first one50of the at least one solar cell18includes a first plurality of the solar cells18, and the second one52of the at least one solar cell18includes a second plurality of the solar cells18.

Referring toFIGS.2A and2C, in certain embodiments, the second layer14extends intermediate the third and fourth ends24,26of the first layer12. In certain embodiments, the first layer includes a first step flap54adjacent the third end32of the second layer14and a second step flap56adjacent the fourth end34of the second layer14. In certain embodiments, the first step flap54includes a length L1extending from the third end32of the second layer14to the third end24of the first layer12. In certain embodiments, the first step flap54includes a width W3extending from the first end20of the first layer12to the second end22of the first layer12. In certain embodiments, the second step flap56includes a length L2extending from the fourth end34of the second layer14to the fourth end26of the first layer12. In certain embodiments, the second step flap56includes a width W4extending from the first end20of the first layer12to the second end22of the first layer12. In certain embodiments, the width W3is equal to the width W4. In certain embodiments, the length L1and is equal to the length L2. In certain embodiments, the head lap16, the first step flap54, and the second step flap56are contiguous. In certain embodiments, the second layer14extends from the third end24of the first layer12to a location intermediate the third and fourth ends24,26of the first layer12. In certain embodiments, the first layer12includes the second step flap56adjacent the fourth end34of the second layer14. In certain embodiments, the head lap16and the second step flap56are contiguous.

In certain embodiments, the second layer14extends from the fourth end26of the first layer12to a location intermediate the third and fourth ends24,26of the first layer12. In certain embodiments, the first layer12includes the first step flap54adjacent the third end32of the second layer14. In certain embodiments, the head lap16and the first step flap54are contiguous. In certain embodiments, each of the first layer12and the second layer14is composed of a polymer. In certain embodiments, each of the first layer12and the second layer14is composed of thermoplastic polyolefin (TPO). In certain embodiments, each of the first layer12and the second layer14is composed of polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyarylate (PAR), polyetherimide (PEI), polyarylsulfone (PAS), polyethersulfone (PES), polyamideimide (PAI), or polyimide; polyvinyl chloride (PVC); ethylene propylene diene monomer (EPDM) rubber; silicone rubber; fluoropolymers-ethylene tetrafluoroethylene (ETFE), polyvinylidene fluoride (PVDF), tetrafluoroethylene-hexafluoropropylene copolymers (FEP), and tetrafluoroethylene20 hexafluoropropylene-vinylidene fluoride copolymers (THV), or blends thereof. In certain embodiments, the first layer12and the second layer14are laminated. In certain embodiments, the second layer14is ultrasonically welded to the first layer12. In certain embodiments, the second layer14is heat welded to the first layer12. In certain embodiments, the second layer14is thermally bonded to the first layer12. In certain embodiments, the plurality of photovoltaic shingles10is installed on a roof deck200. In certain embodiments, the roof deck200may be made of wood or other non-conductive materials and may be the surface upon which photovoltaic shingles10are secured. In certain embodiments, the roof deck200may comprise roofing material that resides between the structural componentry of a roof (e.g. trusses, joists, and/or other structural componentry) and the waterproofing or other layers upon which shingles10may be placed. In certain embodiments, the plurality of photovoltaic shingles10is installed directly to the roof deck200. In certain embodiments, each of the plurality of photovoltaic shingles10is installed on the roof deck200by a plurality of fasteners58. In certain embodiments, the plurality of fasteners58are installed through the head lap16. In certain embodiments, the plurality of fasteners58includes a plurality of nails.

Referring toFIG.2E, in certain embodiments, each of the plurality of photovoltaic shingles10is installed on the roof deck200by an adhesive60. In certain embodiments, the adhesive60is adhered directly to the roof deck200. In certain embodiments, the adhesive60is adhered to an underlayment. In certain embodiments, the underlayment is adhered directly to the roof deck200. In certain embodiments, the adhesive60is located on a rear surface62of the photovoltaic shingle10. In certain embodiments, the adhesive60includes at least one adhesive strip. In certain embodiments, the adhesive60includes a plurality of adhesive strips. In certain embodiments, the plurality of adhesive strips is arranged intermittently. In certain embodiments, the adhesive60is located proximate to one edge of the photovoltaic shingle10. In certain embodiments, the adhesive60is a peel and stick film sheet. In certain embodiments, the peel and stick film sheet includes at least one sheet of film removably attached to the rear surface62. In certain embodiments, the peel and stick film sheet is composed of EverGuard Freedom HW peel and stick membrane manufactured by GAF. In certain embodiments, the adhesive60includes polyvinyl butyrate, acrylic, silicone, or polycarbonate. In certain embodiments, the adhesive60includes pressure sensitive adhesives.

In certain embodiments, the system5includes an underlayment layer202installed on the roof deck200(seeFIG.6). In certain embodiments, the plurality of photovoltaic shingles10overlay the underlayment layer202. Referring toFIGS.1A through1D, in certain embodiments, one of the plurality of photovoltaic shingles10overlays the head lap16of another of the plurality of photovoltaic shingles10. In certain embodiments, one of the plurality of photovoltaic shingles10overlays the first section38and the second section40of the another of the of the plurality of photovoltaic shingles10for a staggered installation of the photovoltaic shingles10. In certain embodiments, the first section38of the one of the plurality of photovoltaic shingles10overlays the first section38and the second section40of the another of the of the plurality of photovoltaic shingles10. In certain embodiments, the second section40of the one of the plurality of photovoltaic shingles10overlays the first section38and the second section40of the another of the of the plurality of photovoltaic shingles10.

Referring toFIGS.2A through2D, in certain embodiments, the first step flap54of one of the plurality of photovoltaic shingles10overlays the first step flap54of another of the plurality of photovoltaic shingles10, and the second step flap56of the one of the plurality of photovoltaic shingles10overlays the second step flap56of the another of the plurality of photovoltaic shingles10for a non-staggered installation of the photovoltaic shingles10. In certain embodiments, the first step flap54of the one of the plurality of photovoltaic shingles10substantially aligns with the first step flap54of the another of the plurality of photovoltaic shingles10, and the second step flap56of the one of the plurality of photovoltaic shingles10substantially aligns with the second step flap56of the another of the plurality of photovoltaic shingles10. In certain embodiments, the third end32of the second layer14of the one of the plurality of photovoltaic shingles10substantially aligns with the third end32of the second layer14of the another of the plurality of photovoltaic shingles10, and the fourth end34of the second layer14of the one of the plurality of photovoltaic shingles10substantially aligns with the fourth end34of the second layer14of the another of the plurality of photovoltaic shingles10. In certain embodiments, the second step flap56of one of the plurality of photovoltaic shingles10overlays the first step flap54of another of the plurality of photovoltaic shingles10.

Referring toFIGS.3A through5, in certain embodiments, the system5includes at least one wireway100installed proximate to the plurality of photovoltaic shingles10on the roof deck200. In certain embodiments, the at least one wireway100is installed intermediate the plurality of photovoltaic shingles10. In certain embodiments, the at least one wireway100is installed proximate to each of the third ends32of the second layers14. In certain embodiments, the at least one wireway100overlays each of the first step flaps54. In certain embodiments, the at least one wireway100is installed proximate to each of the fourth ends34of the second layers14. In certain embodiments, the at least one wireway100overlays each of the second step flaps56. In certain embodiments, the at least one wireway100is installed intermediate each of the third ends32of a first plurality of the photovoltaic shingles10and the fourth ends34of a second plurality of the photovoltaic shingles10. In certain embodiments, the at least one wireway100overlays each of the first step flaps54. In certain embodiments, the at least one wireway100overlays each of the second step flaps56. In certain embodiments, the step flaps54,56form the wireway100.

Referring toFIGS.6through9, in certain embodiments, the at least one wireway100includes a pair of rails102spaced apart from one another. In certain embodiments, the rails102extend outwardly from the roof deck200. In certain embodiments, the rails102are substantially parallel to another. In certain embodiments, each of the rails102includes side flashing104. In certain embodiments, each of the side flashing104includes a first portion106positioned on the roof deck200and second portion108extending obliquely and inwardly in a first direction relative to the first portion106. In certain embodiments, slots109are formed between the first portions106and the second portions108. In certain embodiments, the at least one wireway100is rectangular in shape. In certain embodiments, the photovoltaic shingles10overlay the second portion108of the side flashing104. In certain embodiments, the at least one wireway100is sized and shaped to receive electrical components of a photovoltaic system, such as an electrical junction box, electrical wire, and electrical connectors. Still referring toFIGS.6through9, in certain embodiments, the at least one wireway100includes a lid110. In certain embodiments, the lid110is removably attached to the at least one wireway100. In certain embodiments, the lid110includes a cover portion112and a pair of rails114spaced apart from one another and extending obliquely and inwardly in a second direction opposite the first direction of the second portion108of the rails102. In certain embodiments, the10lid110is removably engaged with the side flashing104of the wireway100such that the rails114of the lid110engage (e.g., snap-in) the second portions108of the side flashing104. In certain embodiments, the lid110is substantially rectangular in shape. In certain embodiments, the rails114extend outwardly and obliquely in the first direction. In certain embodiments, the lid110is removably attached to the at least one wireway100by screws, nails, rivets, adhesives or other fasteners. In certain embodiments, bands128mimic the appearance of the photovoltaic shingles10to provide a blended aesthetic look between the lids110, the photovoltaic shingles10, and a plurality of roofing shingles204of the roofing system5(seeFIG.10).

Referring toFIGS.11and12, in certain embodiments, the at least one solar cell18includes an electrical bussing140and at least one electrical connector142electrically connected to the electrical bussing140. In certain embodiments, the at least one electrical connector142is positioned on the head lap16. In certain embodiments, the at least one electrical connector142includes a first electrical connector142aand a second electrical connector142b. In certain embodiments, the first electrical connector142ais positioned proximate to the third end24and the second electrical connector142bis positioned proximate to the fourth end26. In certain embodiments, the first electrical connector142aof one of the plurality of photovoltaic shingles10is connected to the second electrical connector142bof another of the plurality of photovoltaic shingles10. In certain embodiments, the first electrical connector142ais a plug connector and the second electrical connector142bis a socket connector. In certain embodiments, the first and second electrical connectors142a,142bare connected to one another by an electrical wire144(secFIGS.11and12). In certain embodiments, the first and second electrical connectors142a,142bare removably connected to one another.

Referring toFIGS.13and14, in certain embodiments, a photovoltaic module1110includes an active area1109having a plurality of solar cells1112. In certain embodiments, the photovoltaic module1110includes an inactive area comprising a headlap portion1113, a first side lap1115located at one end of the photovoltaic module1110, and a second side lap1117located at an opposite end of the photovoltaic module1110. In certain embodiments, the headlap portion1113is textured. In certain embodiments, the texture of the headlap portion1113is different from a texture of the solar cells1112. In certain embodiments, a wire cover bracket1300is attached to the first side lap1115. In certain embodiments, the wire cover bracket1300includes a junction box1423. Details of the wire cover bracket1300shall be provided hereinbelow. In certain embodiments, the plurality of solar cells1112includes a first set of solar cells1112aand a second set of solar cells1112b. In certain embodiments, the first set of solar cells1112aincludes eight of the solar cells1112. In certain embodiments, the second set of solar cells1112bincludes eight of the solar cells1112. In certain embodiments, each of the first set of solar cells1112aand the second set of solar cells1112bincludes more or less than eight of the solar cells1112. In certain embodiments, a last one of the solar cells1112of the first set of solar cells1112ais separated by a first one of the solar cells1112of the second set of solar cells1112bby a space S. In certain embodiments, the space S is located approximately half the length of the photovoltaic module1110. In certain embodiments, the solar cells1112of each of the first and second sets of solar cells1112a,1112bare strung together with bussing1101. In certain embodiments, the bussing1101includes nine bussing wires. In certain embodiments, the bussing1101may include more or less than the nine bussing wires. In certain embodiments, a first bussing wire1103aextends from the first side lap1115to the space S. In certain embodiments, the first bussing wire1103aextends to approximately half the length of the photovoltaic module1110. In certain embodiments, one end of the first bussing wire1103ais electrically connected to the junction box1423and the other end of the first bussing wire1103ais electrically connected to the first set of solar cells1112a. In certain embodiments, a second bussing wire1103bextends from the first side lap1115to a location proximate to the second side lap1117. In certain embodiments, the second bussing wire1103bextends substantially the entire length of the photovoltaic module1110. In certain embodiments, one end of the second bussing wire1103bis electrically connected to the junction box1423and the other end of the second bussing wire1103bis electrically connected to the second set of solar cells1112b. In certain embodiments, each of the first bussing wire1103aand the second bussing wire1103bis covered with a polymer layer. In certain embodiments, each of the first bussing wire1103aand the second bussing wire1103bis covered with expanded polyethylene (“EPE”). In certain embodiments, the EPE is comprised of a black strip. In certain embodiments, each of the first bussing wire1103aand the second bussing wire1103bis coated with a colorant or dye to reduce reflectivity. In certain embodiments, the plurality of solar cells1112includes a plurality of the solar cells1112. In certain embodiments, the plurality of solar cells1112is arranged in one row (i.e., one reveal). In certain embodiments, the plurality of solar cells1112is arranged in two rows (i.e., two reveals). In certain embodiments, the plurality of solar cells1112is arranged in three rows (i.e., three reveals). In certain embodiments, the plurality of solar cells1112is arranged in four rows (i.e., four reveals). In certain embodiments, the plurality of solar cells1112is arranged in five rows (i.e., five reveals). In certain embodiments, the plurality of solar cells1112is arranged in six rows (i.e., six reveals). In certain embodiments, the plurality of solar cells1112is arranged in more than six rows.

Referring toFIG.15, in certain embodiments, the photovoltaic system1400is installed on the roof deck1402. In certain embodiments, an additional, non-active (i.e., “dummy”) wireway1480and associated cover1304, similar to the at least one wireway1422and the associated covers1304, may be installed on the end of the second subarray S2for symmetry and aesthetics. In certain embodiments, the non-active wireway1480is installed over the second side laps1117of the photovoltaic modules1110b. In certain embodiments, the non-active wireway1480does not include any electrical components or electrical wiring. In certain embodiments, the non-active wireway1480is optional and need not be included. In certain embodiments, roofing shingles overlay the second side laps1117of the photovoltaic modules1110bof the second subarray S2. In certain embodiments, it should be understood that the non-active wireway1480or roofing shingles may overlay the second side laps1117of the photovoltaic modules1110aof the first subarray S1in the absence of the second subarray S2.

Referring toFIG.16, in certain embodiments, an exemplary rapid shutdown device1606in a rapid shutdown device system1600is schematically illustrated. In certain embodiments, the rapid shutdown device1606may be utilized with any of the photovoltaic shingles, modules, and systems ofFIGS.1-15. In certain embodiments, the rapid shutdown device1606may be configured to stop or reduce the voltage and current generated or otherwise coming from a photovoltaic string1624of photovoltaic modules1622, such as a photovoltaic string1624installed on a roof or other part of a structure, such as, but not limited to, a building, a home, an office, a telephone pole, an antenna, a farm, any type of physical structure, or any combination thereof. Such a capability is especially desirable in the event that a hazard is present in a vicinity of the structure, the photovoltaic string1624, the general environment in which the structured is located, or any combination thereof. The hazard, for example, may be a fire, an event that that increases susceptibility to electric shock, a temperature or temperature range, weather-related hazards (e.g., hail, storms, wind, etc.), moisture, humidity, malfunctioning of a photovoltaic module, an electrical short, any type of hazard, or any combination thereof. In certain embodiments, the rapid shutdown device may include a switch (e.g., disconnect switch1620) that may act as an on/off switch for the photovoltaic string1624. In certain embodiments, for example, the rapid shutdown device1606may include a single (i.e., monopole) disconnect switch1620so that one location in one of the power lines (e.g., power line1626) may be opened.

In certain embodiments, the rapid shutdown device system1600may include a grid supply1602, an inverter1604(e.g., an AC to DC inverter configured to convert direct current into alternating current usable by the grid supply1602, a rapid shutdown device1606, a first power line1626, a second power line1628, a housing1630to enclose some or all of the rapid shutdown device1606(e.g., a housing comprising a non-conductive material), photovoltaic modules1622, one or more sensors1623, a photovoltaic string1624containing one or more photovoltaic modules1622, any other componentry, or any combination thereof. In certain embodiments, the grid supply1602(or grid power supply) may be an AC grid that may serve as the componentry and/or location at which the rapid shutdown device system1600connects to an electrical grid, such as provided by a utility company. In certain embodiments, the grid supply1602may include grid connection equipment to facilitate connection of the photovoltaic string1624and system1600to the electrical grid. Power generated by the photovoltaic modules1622of the photovoltaic string1624may be supplied to the grid supply1602for use in the electrical grid, where it may be consumed. In certain embodiments, the inverter1604may be configured to convert direct current electricity generated by the photovoltaic modules1622of the photovoltaic string1624into alternating current electricity that may be utilized by the grid supply1602. In certain embodiments, the alternating current electricity may be utilized to power electrical devices and systems within, on, around, or otherwise in a vicinity of the structure (e.g., a home) upon which the rapid shutdown device system1600is secured.

In certain embodiments, the photovoltaic modules1622may be any type of photovoltaic modules that may be configured to generate energy, such as direct current electricity, based on exposure of surfaces of the photovoltaic modules1622to light, such as sunlight. In certain embodiments, the photovoltaic string1624may include one or more photovoltaic modules1622that may be electrically connected in series, parallel, or other electrical configuration. In certain embodiments, photovoltaic string1624may include two or more photovoltaic modules1622, three or more photovoltaic modules1622, four or more photovoltaic modules, or any number of photovoltaic modules1622. In certain embodiments, a plurality of photovoltaic modules1622may include at least two photovoltaic modules1622.

In certain embodiments, the rapid shutdown device1606may include and/or be connected to a plurality of componentry. For example, in certain embodiments, the rapid shutdown device1606may include, but is not limited to including, a discharge circuit1608, a receiver filter1614, a receiver circuit1616, an internal power supply1618, a gate drive circuit1619, a rapid shutdown switch1620(i.e., a disconnect switch1620), a housing1630configured to house the rapid shutdown device1606, or any combination thereof. In certain embodiments, the componentry of the rapid shutdown device1606may be connected to a first power line1626, a second power line1628, or any combination thereof. In certain embodiments, for example, the discharge circuit1608, the receiver filter1614, the internal power supply1618, or any combination thereof, may be connected to both the first power line1626and the second power line1628. In certain embodiments, the rapid shutdown switch1620may only be connected to the first power line1626. In certain embodiments, the receiver circuit1616may be connected to the internal power supply1618, the gate drive circuit1619, the receiver filter1614, or any combination thereof. In certain embodiments, the gate drive circuit1619may be connected to the receiver circuit1616, the internal power supply1618, and the rapid shutdown device switch1620.

In certain embodiments, the sensors1623may optionally be included in the rapid shutdown device system1600. In certain embodiments, the sensors1623or other componentry may be configured to measure the operating status associated with each photovoltaic module1623of the photovoltaic string1624. In certain embodiments, the rapid shutdown device system1600may be configured to measure the operative status without the need for the sensors1623. In certain embodiments, the sensors1623may be on the photovoltaic modules1622, in a vicinity of the photovoltaic modules1622, in a vicinity of the rapid shutdown device1606, in and/or on the rapid shutdown device1606, and/or any other location at which sensor data may be obtained relating to the photovoltaic string1624. In certain embodiments, the sensors1623may include, but are not limited to, humidity sensors, temperature sensors, pressure sensors, motion sensors, cameras, laser scanners, accelerometers, gyroscopes, light sensors, acoustic sensors, any type of sensors, or any combination thereof. In certain embodiments, the sensor data obtained from the sensors1623may indicate an operating status including, but not limited to, a temperature, a temperature rise, an electrical arc event, a moisture level, a voltage, an amperage, a wattage, a malfunction, a weather event, a tampering event, a movement (e.g., of the modules or movement of an object in a vicinity of the string1624), a speed of the movement, a light change, a sound (e.g., a sound of thunder or other sound indicative of potential or actual hazardous conditions), any type of operating status, or any combination thereof. In certain embodiments, the operating status may be utilized to determine whether or not a hazard that may impact the performance of the photovoltaic string1624, cause potential injury, cause damage to the componentry of the photovoltaic string1624, roof, and/or structure, any other type of hazard, or any combination thereof.

For the rapid shutdown device1606and system1600, upon the receipt of an electronic photovoltaic string status signal including sensor data from the one or more sensors1623, the rapid shutdown device1606may determine the presence of a hazard based on the sensor data included in the status signal. If there is no hazard, the rapid shutdown device1606may keep the switch1620in a closed configuration such that the electrical connection between the photovoltaic string1624and the inverter1604and grid supply1602is maintained. On the other hand, if the rapid shutdown device1606detects that a hazard is present based on the status signal, the rapid shutdown device1606may cause the switch1620to open, thereby disconnecting the electrical connection between the photovoltaic string1624and the inverter1604and grid supply1602. When the switch1620is opened, the discharge switch1612of the discharge circuit may operate complementary to the switch1620to establish with the discharge resistor1610a discharge path between the positive and negative terminals of the rapid shutdown device1606. For example, in certain embodiments, when the switch1620is closed, the discharge switch1612may be opened and vice versa.

In certain embodiments, the disconnect switch1620may be a high voltage switch that may be configured to disconnect the first power line1626when the disconnect switch1620is open. In certain embodiments, the high voltage switch may be a switch for disconnecting or connecting electrical circuits handling voltage ranges of greater than 1000 AC RMS voltage or greater than 1500 DC voltage. In certain embodiments, high voltage may mean any voltage capable of facilitating electrical arc generating or causing injury risk or harm to a person or animal. In certain embodiments, the disconnect switch1620may have a blocking voltage exceeding a string voltage associated with power generated by the photovoltaic string1624. The power associated with the string voltage may be generated, such as when the photovoltaic modules1622are exposed to sunlight while installed on a roof of a structure. Once the sensors1623generate sensor data by conducting measurements associated with the operating status of the photovoltaic string1624, the sensors1623may transmit at least one electronic photovoltaic string status signal to a communication circuit of the rapid shutdown device system1600. In certain embodiments, the communication circuit may include one or more of the componentry illustrated inFIG.16. For example, the communication circuit may include the receiver filter1606, the receiver circuit1616, the power supply1618(e.g., internal power supply), other componentry, or any combination thereof. In certain embodiments, the rapid shutdown device1600may include the receiver circuit1616and power circuit, which may include gate drive circuit1619. In certain embodiments, the receiver circuit1616may serve as the receiving end of the communication protocol between the rapid shutdown device1606and inverter1604, which may be configured to receive the stay-on or shutdown command and enable the photovoltaic cells of the string1624to generate power or stop generating power accordingly. The communication may be implemented through a hard wire and utilize protocols such as serial, CAN, etc. or custom logic codes or analog voltage levels. In certain embodiments, wireless communication may be implemented such as WiFi, Zigbee, and the like. In certain embodiments, PLC may be used so that the data is modulated through the power lines/cables connecting the inverter1604to the string of photovoltaic cells/modules1624. When using PLC, the receiver filter1606may be configured to extract the signal sent through the power line (e.g., power line1626). In certain embodiments, a demodulator circuit of the communication circuit may translate the PLC signal containing an electronic photovoltaic string status/operating status to a status command, which may be utilized to determine the configuration of the power circuit containing the gate drive circuit1619(e.g., disconnect the switch or have the switch remain closed). For example, if the operating status indicates the presence of a hazard, the command may be utilized to cause the switch1620to open, thereby disconnecting the photovoltaic string1624from a grid power supply1602, inverter1604, and/or other componentry.

In certain embodiments, the internal power supply1618may be configured to reduce the power generated by the photovoltaic string1624to a high voltage switch power associated with drive the disconnection switch1620(i.e., the high voltage switch). In certain embodiments, the internal power supply1618may be configured to power one or more of the circuits of the rapid shutdown device1606. In certain embodiments, the internal power supply1618may be configured to remove noise and variance from power generated by the photovoltaic string1624. In certain embodiments, the receiver filter1606may be configured to detect at least one power line communication (or other type of communication) comprising the at least one electronic photovoltaic string status signal, such as may be provided by a sensor (e.g. sensor1623) measuring data associated with the photovoltaic cells1624. The receive filter1606may provide the communication including the signal to the receiver circuit1616, which may demodulate the communication and generate a command for the rapid shutdown device1600to either stay closed (on) or disconnect (off). In certain embodiments, if the rapid shutdown device1600disconnects the electrical connection by opening the switch1620, the inverter voltage may be discharged either through the discharge circuit1608built-into the inverter1604or in the rapid shutdown device1600.

In certain embodiments, the gate drive circuit1619may be configured to receive the electronic photovoltaic string status signal indicative of the operating status of the photovoltaic string1624. In certain embodiments, the gate drive circuit1619may be configured to utilize the high voltage switch power form the internal power supply1618to generate a high voltage switch command signal to drive the disconnect switch1620(i.e., the high voltage switch). In certain embodiments, the gate drive circuit1619may be configured to determine that the operating status of the photovoltaic string1624is indicative of a hazard base based on analyzing the at least one electronic photovoltaic string status signal. In certain embodiments, the operating status may be indicative of a hazard based on the sensor data and/or status signal satisfying a threshold value associated with a hazard (e.g., threshold temperature, moisture, etc.), indicating occurrence of an event (e.g., a camera detected that a portion of a module1622has been damaged, that moisture has seeped into a portion of the module1622, that a storm is present, etc.), Based on the operating status indicating the hazard, the gate drive circuit1619may be configured to generate a high voltage switch command signal to cause the disconnect switch1620to open so as to disconnect the photovoltaic string1624from at least one electrical connection to a grid power supply1602with the block voltage exceeding the string voltage. In certain embodiments, the high voltage switch command signal may be an electrical signal that may be utilized be utilized to activate the switch to close or open. When the disconnect switch1620is opened, the rapid shutdown device1606may rapidly shutdown the photovoltaic string1624and its modules1622via the disconnect switch1620.

Referring now also toFIG.17, rapid shutdown device1706and system1700according to embodiments of the present disclosure is shown. In certain embodiments, the rapid shutdown device1706and system1700may include any of the componentry and functionality provided by the rapid shutdown device1606and system1600. According to embodiments ofFIG.17, the rapid shutdown device system1700may include a grid supply1702(e.g., AC grid), an inverter1704(e.g., string inverter), a rapid shutdown device1706, a first disconnection switch1720(i.e., S2) on a first power line1726, a second disconnection switch1721(i.e., S3) on a second power line1728, a discharge switch1712(i.e., S1), a discharge resistor1710, a plurality of photovoltaic modules1722, sensors1723and a photovoltaic string1724including one or more photovoltaic modules1722. In the configuration ofFIG.17, the disconnection switch1720and the disconnection switch1721may serve as a dipole configuration, whereby the circuit is opened or closed to disconnect or reconnect the photovoltaic string1724from an electrical connection with the inverter1704and/or grid supply1702based on the opening or closing of both disconnection switches1720,1721.

In certain embodiments, the sensors1723may optionally be included in the rapid shutdown device system1700. In certain embodiments, the sensors1723or other componentry may be configured to measure the operating status associated with each photovoltaic module1722of the photovoltaic string1724. In certain embodiments, the rapid shutdown device system1700may be configured to measure the operative status without the need for the sensors1723. In certain embodiments, the sensors1723may be on the photovoltaic modules1722, in a vicinity of the photovoltaic modules1722, in a vicinity of the rapid shutdown device1706, in and/or on the rapid shutdown device1706and/or any other location at which sensor data may be obtained relating to the photovoltaic string1724. In certain embodiments, the sensors1723may include, but are not limited to, humidity sensors, temperature sensors, pressure sensors, motion sensors, cameras, laser scanners, accelerometers, gyroscopes, light sensors, acoustic sensors, any type of sensors, or any combination thereof. In certain embodiments, the sensor data obtained from the sensors1723may indicate an operating status including, but not limited to, a temperature, a temperature rise, an electrical arc event, a moisture level, a voltage, an amperage, a wattage, a malfunction, a weather event, a tampering event, a movement (e.g., of the modules or movement of an object in a vicinity of the string1724), a speed of the movement, a light change, a sound (e.g., a sound of thunder or other sound indicative of potential or actual hazardous conditions), any type of operating status, or any combination thereof. The operating status may be utilized to determine whether or not a hazard that may impact the performance of the photovoltaic string1724, cause potential injury, cause damage to the componentry of the photovoltaic string1724, roof, and/or structure, any other type of hazard, or any combination thereof.

For the rapid shutdown device1706and system1700, upon the receipt of a status signal including sensor data from the one or more sensors1723, the rapid shutdown device1706may determine the presence of a hazard based on the sensor data included in the status signal. If there is no hazard, the rapid shutdown device1706may keep the switches1720,1721in a closed configuration such that the electrical connection between the photovoltaic string1724and the inverter1704and grid supply1702is maintained. On the other hand, if the rapid shutdown device1706detects that a hazard is present based on the status signal, the rapid shutdown device1706may cause the switches1720,1721to open, thereby disconnecting the electrical connection between the photovoltaic string1724and the inverter1704and grid supply1702. When the switches1720,1721are opened, the discharge switch1712of the discharge circuit may operate complementary to the switches1720,1721to establish with the discharge resistor1710a discharge path between the positive and negative terminals of the rapid shutdown device1706. For example, in certain embodiments, when the switches1720,1721are closed, the discharge switch1721may be opened and vice versa.

In certain embodiments, the sensors1723may generate further sensor data that are included in a different electronic photovoltaic status string signal associated with a subsequent operating status of the photovoltaic string. The rapid shutdown device1706and system1700may determine, based on the different string signal that the subsequent operating status indicates that the hazard is no longer present. Based on the subsequent operating status indicating that the hazard is no longer present, the rapid shutdown device1706and system1700may generate a switch command signal that may be configured to cause the switches1720,1721to close so as to reconnect the photovoltaic string1724to the electrical connection connecting the photovoltaic string1724to the inverter1704and grid supply1702.

Referring now also toFIG.18, an exemplary block diagram of a rapid shutdown device system1800that may be utilized to support the functionality described in the present disclosure is schematically illustrated. In certain embodiments, the rapid shutdown device system1800may include a plurality of componentry to support the functionality described in the present disclosure. In certain embodiments, the plurality of componentry may include, but is not limited to, photovoltaic cells (e.g., in 16-cell modules and/or strings of modules)1802, power supplies1804, a receiver passive filter1806, a receiver1808(e.g., a receiver circuit), a power circuit1810(e.g., for disconnecting or bypassing electrical connections), a string inverter1812, any other componentry, or a combination thereof. In certain embodiments, the photovoltaic cells1802and/or the photovoltaic string containing the cells1802may be configured to be installed on a roof to generate energy from sunlight contacting the photovoltaic cells1802and/or the modules of the photovoltaic string. The energy may then be converted from direct current electricity to alternating current electricity so that the energy generated by the cells1802may be utilized for appliances, electronic devices, and/or an electrical grid connected to the cells1802and/or photovoltaic string.

In certain embodiments, multiple power supplies1804may be implemented for different sub-circuits of the rapid shutdown device of the rapid shutdown device system1800(or other rapid shutdown devices described in the present disclosure). For example, a power supply1804may be utilized for the receiver circuit1808and another power supply1804may be utilized for the power circuit1810. In certain embodiments, one power supply1804may be used for multiple components or sub-circuits of the rapid shutdown device. In certain embodiments, the receiver passive filter1806may be connected to the string inverter1812(configured to convert direct current energy output to alternating current energy output) and to power lines connecting the componentry of the rapid shutdown device system1802together. In certain embodiments, the receiver passive filter1806may be configured to detect at least one power line communication (or other type of communication) comprising the at least one electronic photovoltaic string status signal, such as may be provided by a sensor (e.g. sensor1623) measuring data associated with the photovoltaic cells1802.

In certain embodiments, the rapid shutdown device1800may include a communication circuit that includes one or more of the componentry illustrated inFIG.18, for example. For example, the communication circuit may include the receiver passive filter1806, the receiver circuit1808, the power supply1804(e.g., internal power supply), other componentry, or any combination thereof. In certain embodiments, key sub-circuits of the rapid shutdown device1800may include the receiver circuit1808and power circuit1810. In certain embodiments, the receiver circuit1808may serve as the receiving end of the communication protocol between the rapid shutdown device1802and inverter1812, which may be configured to receive the stay-on or shutdown command and enable the photovoltaic cells1802of the string to generate power or stop generating power accordingly. The communication may be implemented through a hard wire and utilize protocols such as serial, CAN, etc. or custom logic codes or analog voltage levels. In certain embodiments, wireless communication may be implemented such as WiFi, Zigbee, and the like. In certain embodiments, PLC may be used so that the data is modulated through the power lines/cables connecting the inverter1812to the string of photovoltaic cells/modules1802. When using PLC, the receiver passive filter1806may be configured to extract the signal sent through the power line. In certain embodiments, a demodulator circuit of the communication circuit may translate the PLC signal containing an electronic photovoltaic string status/operating status to a status command, which may be utilized to determine the configuration of the power circuit1810(e.g., disconnect the switch or have the switch remain closed). For example, if the operating status indicates the presence of a hazard, the command may be utilized to cause the switch to open, thereby disconnecting the string of cells1802from a grid supply, inverter1812, and/or other componentry.

In certain embodiments, the communication circuit may be also implemented by a bidirectional receiver/transmitter method or process. In such a scenario, in addition to the primary function of the rapid shutdown device receiver circuit1808, other information may be transmitted back to the inverter1812, user of the rapid shutdown device system, other devices, or any combination thereof. In certain embodiments, the power circuit1810may include switching devices (e.g. voltage switches), such as relays or solid-state switches such as MOSFET, IGBT, or thyristors. In certain embodiments, the switches may be configured according to the status signal. An exemplary configuration of the power circuit includes two switches (e.g., S2and S3inFIG.17). When the switches are open, the photovoltaic cells of the string of cells1802may be disconnected from the inverter1812. When the switches are closed, the string of photovoltaic cells1802may be energized and connected to the inverter1812. In certain embodiments, only one switch may be employed in the power circuit1810, such as in a monopole configuration. For example, either one of S2or S3may remain in the circuit and the other switch may be replaced with a conductive connection.

In certain embodiments, the rapid shutdown device1800may include a discharge circuit that may include a switch and discharge resistor (e.g., S1and R1inFIG.17or Sdand RdinFIG.16) to de-energize any charge at the output of the inverter1812. In such an implementation, S1may be closed when S2and/or S3are open and S1may be closed when those switches are closed. As a result, the status of S1may be complementary to the status of S2and S3. In certain embodiments, the discharge circuit may be transformed to the inverter1812and not implemented within the rapid shutdown device1800. In certain embodiments, the receiver circuit1808outputs a command to the power circuit1810. The command may be changed according to the state of operation through a gate drive circuit. In certain embodiments, the rapid shutdown device1800may be configured to incorporate any of the functionality and/or componentry of the other rapid shutdown devices and/or systems described herein.

In certain embodiments, the rapid shutdown devices described in the present disclosure may come in a variety of form factors. In certain embodiments, the form-factors for the rapid shutdown devices and/or systems may be designed to match the functionality and aesthetics of a building-integrated photovoltaic module system or in-roof solar system. Referring now also toFIG.19, a rapid shutdown device1900is shown that has a flat design designed to fit within a transition box utilized with the photovoltaic string and rapid shutdown device and/or system. Additionally, in certain embodiments, the flat design of the rapid shutdown device1900may be such that the thickness of the rapid shutdown device1900is substantially lower than the length and the width of the device, as shown inFIG.19. In certain embodiments, the rapid shutdown device1900may be sized and shaped to fit any type of enclosure, such as an enclosure that may be mounted onto a roof, an enclosure in an attic, an enclosure on a wall adjacent to the photovoltaic string, or any combination thereof. In certain embodiments, the rapid shutdown device1900may include and/or be connected to an inverter1902and an array of photovoltaic cells and/or modules1904.

As another form-factor example and referring now also toFIG.20, a rapid shutdown device2000is shown that has a slim design, where the length of the design is configured to be long than the width and length of the rapid shutdown device2000. In certain embodiments, the rapid shutdown device2000may be electrically connected to an inverter and an array (or substring) of photovoltaic modules. In certain embodiments, the rapid shutdown device2000is sized and shaped to fit in a wireway, wire-channel, wire duct, or any combination thereof. In certain embodiments, the rapid shutdown device2000(or other rapid shutdown devices and systems described herein) may be configured to support various electrical system ratings including, but not limited to, a maximum system voltage of 600 VDC, a rated input current of 10 A DC, and a rated input operating voltage of between 50-550 V DC. In certain embodiments, the rapid shutdown devices may be configured to support various communication and other requirements. In certain embodiments, the rapid shutdown devices of the present disclosure may utilize a monopole method of disconnecting the photovoltaic string from the electrical connection to the grid supply. In certain embodiments, the method of disconnection may be dipole (i.e., having a disconnection switch on two power lines connected to the photovoltaic string and the grid supply and/or inverter.

In certain embodiments, the control signal technology utilized may involve the use of PLC circuitry and two-way PLC as an added benefit to the performance of the rapid shutdown device and/or system. In certain embodiments, the system voltage at the output (i.e., after a disconnect occurs) may include having an open circuit (i.e., complies with NEC 2014 <30 V in 30 seconds). In certain embodiments, the rapid shutdown systems may include bleeding resistors in a first configuration (i.e., bleeding circuit may be within the rapid shutdown device). In certain embodiments, the rapid shutdown device systems may include bleeding resistors in a second configuration (e.g., bleeding circuit is out of the rapid shutdown device itself).

In certain embodiments, the rapid shutdown devices may be configured to support various thermal and performance requirements. For example, in certain embodiments, the operating temperature for the rapid shutdown devices and/or systems may range from 40 to 185° F. (−40 to 85° C.), the ambient temperature (max) may be above 40° C. with a target temperature of 50° C., the protection utilized may be over-temperature shutdown above safe operation of the photovoltaic string and/or rapid shutdown system, the device-power consumption may be such that thermal requirements are satisfied, the storage temperature for the rapid shutdown devices and/or systems may range from −40 to 185° F. (−40 to 85° C.), the humidity for the rapid shutdown devices and/or systems may range from 0-100%, the operating altitude may range from 2000 m to a target of 3500 m above sea level, and the EMC may be such that interference is avoided with arc-fault detection on inverters.

In certain embodiments, the rapid shutdown devices may be configured to support various mechanical requirements. In certain embodiments, for example, the rapid shutdown device2000may have dimensions of L×W×D (mm) (e.g., (127−178)+\−3×(25−31.75)+/−1×(17−20)+/−1), have various weights, utilize DC input/output connectors, utilize various cable types and sizes (e.g., PV wire, 14-12 AWG), have various cable lengths (e.g., measured from the housing the rapid shutdown device to the beginning of the connector; 25±5 (In&Out Pos), 127±5 (In&Out Neg)), enclosure materials (e.g., non-metallic without needing any additional group table, and various type of brackets. In certain embodiments, the rapid shutdown devices and systems may also be configured to comply with various standards including, but not limited to, UL1741, UL 61730, UL 1699B to meet AFCI performance, UL 3741 for firefighter's interaction/hazard control, IEC-61000-4-2 for ESD, PVRSE certification, FCC Part 15 Class B, NEC 2014, NEC 2020 Article 690.12, Sunspec PLC, among other standards. In certain embodiments, no heat sink is required for the rapid shutdown device and/or systems described in the present disclosure.

Referring now also toFIG.21, an exemplary method2100for utilizing a rapid shutdown device according to embodiments of the present disclosure. In certain embodiments, the method2100may utilize any of the rapid shutdown devices illustrated inFIGS.13-16and any of the componentry and devices ofFIGS.1-15to perform the operative functionality of the method2100. In certain embodiments, the method2100provides steps for monitoring a photovoltaic string installed on a roof of a structure to detect the presence of hazards the may pose risk of damage to the roof, the structure, the photovoltaic modules of the photovoltaic string, and to individuals that may be in a vicinity of the structure. Upon detection of a hazard, the method2100may include generating a command to cause a high voltage switch connected to a power line connected to the photovoltaic string to open, thereby causing the photovoltaic string to be disconnected from an electric connection to a grid power supply.

At step2102, the method2100may include installing a photovoltaic string including one or more photovoltaic modules on a roof of a structure, such as a building or home. At step2104, the method2100may include monitoring the photovoltaic string by utilizing one or more sensors associated with the photovoltaic string. For example, the sensors may be sensors of photovoltaic modules of the photovoltaic string, sensors in proximity to the photovoltaic modules of the photovoltaic string, sensors capable of sensing operating conditions associated with the photovoltaic string, or any combination thereof. At step2106, the method2100may include receiving, from the one or more sensors and at a receiver filter of a communication circuit of the rapid shutdown device, a power line communication (or other communication based on implementation) including at least one electronic photovoltaic string status signal indicative of an operating status of the photovoltaic string.

At step2108, the method2100may include extracting, such as by utilizing a demodulator circuit of the communication circuit of the rapid shutdown device, the at least one electronic photovoltaic string status signal indicative of the operating status of the photovoltaic string from the electronic photovoltaic string status signal. At step2110, the method2100may include reducing, at the rapid shutdown device componentry, the power generated by the photovoltaic string to a high voltage switch power associated with driving a high voltage switch of the rapid shutdown device. At step2112, the method2100may include providing the at least one electronic photovoltaic string status signal to a gate drive circuit of the rapid shutdown device. At step2114, the method2100may include determining whether the operating status determined from the at least one electronic photovoltaic string status signal indicates the presence of a hazard associated with the photovoltaic string.

If, at step2114, the operating status does not indicate the presence of a hazard, the method2100may proceed to step2116, which may include enabling the photovoltaic string to continue operating. If, however, at step2114, the operating status indicates the presence of a hazard, the method2100may proceed to step2118. At step2118, the method2100may include generating, such as by utilizing the gate drive circuit of the rapid shut down device, a high voltage switch command signal based on the at least one electronic photovoltaic string status signal. In certain embodiments, the high voltage switch command signal may be received by the high voltage switch connected to a power line supporting an electrical connection between the photovoltaic string and a grid supply, such as grid supply connected to an electric grid. The electrical connection may be any type of electrical componentry, structure or connection that allows electricity, communications, or a combination thereof, to flow through the electrical connection and to and/or from any devices and/or componentry connected thereto. At step2120, the method2100may include causing the high voltage switch to open based on the high voltage switch command signal. At step2122, the electrical connection between the photovoltaic string and the grid supply may be disconnected, thereby rapidly shutting down the photovoltaic string and minimizing the potential effects of hazards. In certain embodiments, the method2100may incorporate any of the other functionality, devices, and/or componentry described in the present disclosure and is not limited to the specific steps or sequence of steps illustrated inFIG.21. The method2100may continually operate, operate at intervals, operate based on execution of commands or input devices, or any combination thereof.

The illustrations of arrangements described herein are intended to provide a general understanding of the structure of various embodiments, and they are not intended to serve as a complete description of all the elements and features of devices and systems that might make use of the structures described herein. Other arrangements may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Figures are also merely representational and may not be drawn to scale. Certain proportions thereof may be exaggerated, while others may be minimized. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.

Thus, although specific arrangements have been illustrated and described herein, it should be appreciated that any arrangement calculated to achieve the same purpose may be substituted for the specific arrangement shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments and arrangements of the invention. Combinations of the above arrangements, and other arrangements not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description. Therefore, it is intended that the disclosure is not limited to the particular arrangement(s) disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments and arrangements falling within the scope of the appended claims.

The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of this invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of this invention. Upon reviewing the aforementioned embodiments, it would be evident to an artisan with ordinary skill in the art that said embodiments can be modified, reduced, or enhanced without departing from the scope and spirit of the claims described below.