Design checks

The 46 design checks every solar plan set should pass.

These are the code rules an inspector applies to your single-line diagram. Solar Design Lab runs all 46 of them live as you design, cites the NEC article behind each one, and fixes the mechanical ones for you.

46

automated checks

50

NEC references

10

categories

Looking up a specific article? Jump to the NEC index.

A rejected plan set is rarely wrong. It is usually incomplete.

Almost none of this is hard engineering. It is a long list of small verifications: is that breaker a size you can actually buy, does the conductor carry its load after temperature and conduit-fill corrections, is the grounding electrode conductor sized off the right service conductor, does the backfed breaker fit under the busbar rule. Miss one and the correction notice costs you a week.

The list below is the whole set, generated from the engine itself rather than written by hand, so it is exactly what runs on your design.

Every check, in plain English.

Grouped the way the engine groups them. Each entry gives the rule, what it means in practice, and the NEC article it comes from.

Overcurrent protection

4 checks
  • OCPD Standard Sizes

    Every overcurrent device rating must be in the NEC 240.6(A) standard size table.

    Shows up as: Breaker or fuse rating is not a size you can buy

    Breakers and fuses only come in specific standard sizes (like shoe sizes). This one is set to a size that isn't actually made, so it needs to round to the nearest real size you can buy.

    240.6(A)
  • OCPD vs Conductor Current

    Verify overcurrent protective device rating matches the conductor ampacity it protects.

    Shows up as: Breaker is too large for the conductor it protects

    A breaker is the safety valve for a wire: it has to trip before the wire overheats. Here the breaker is too big for the wire it's protecting, which means the wire could get dangerously hot before the breaker ever shuts off.

    240.4210.20215.3
  • Unprotected Circuits

    Every conductor needs an OCPD at the source unless it qualifies for a tap-rule exception.

    Shows up as: Conductor has no overcurrent device at its source

    Every wire needs a breaker or fuse at the point where its power comes from. This wire doesn't have one, so there's nothing to shut it off if it shorts out.

    240.21
  • OCPD Coordination

    Verify upstream OCPDs are sized at or above downstream OCPDs (selective coordination).

    Breakers should get smaller as you move away from the power source, like branches off a tree trunk. Here a breaker downstream is bigger than the one feeding it, which can let the wrong breaker trip first during a fault.

    240.12700.32

Voltage drop

1 check
  • Voltage Drop

    Branch + feeder voltage drop within recommended limits (≤3% branch, ≤5% total).

    Shows up as: Wire run loses too much voltage over its length

    Electricity loses a little 'push' over long wire runs, like water pressure dropping over a long hose. This run loses too much, which can make equipment underperform: usually fixed by using a thicker wire.

    210.19(A) Informational Note 4215.2(A)(1) Informational Note 2

Voltage rise & interconnection

1 check
  • AC Interconnection Voltage Rise

    Pro

    Grid-tied inverter output conductors: voltage rise ≤2% target / ≤5% over-voltage-trip ceiling (IEEE 1547 + ANSI C84.1 trip window).

    A solar inverter PUSHES power out to the grid, so its wire to the grid gains a little voltage instead of losing it (the opposite of a normal appliance). If it gains too much, the inverter sees the voltage as too high and shuts itself off on the sunniest part of the day: losing production. The fix is a thicker wire or a shorter run.

    IEEE 1547-2018 (OV trip 1.10 p.u.)ANSI C84.1 (Range A +5%)

Grounding & bonding

6 checks
  • EGC Sizing

    Equipment Grounding Conductor sized per NEC 250.122 table based on upstream OCPD rating.

    Shows up as: Equipment grounding conductor is undersized

    The ground wire is the safety path that carries fault current away so a metal enclosure never becomes live. This ground wire is too small for the breaker protecting it and needs to be sized up.

    250.122
  • EGC Inclusion Policy

    Load-side wires must include EGC; supply-side wires to a bonded source must not.

    Ground wires belong on some runs and not others depending on which side of the main service they're on. This run has the ground wire handled the wrong way for its location.

    250.24(A)(5)250.142(B)
  • GEC Sizing

    Grounding Electrode Conductor sized per NEC 250.66 based on service-entrance ungrounded conductor size.

    The main grounding wire that ties your whole system to the earth (via a ground rod or water pipe) is sized off the service conductors. This one doesn't match and needs adjusting.

    250.66
  • Grounding Electrode System Present

    A GES must be connected to the service-entrance equipment.

    The system has to be physically tied to the earth through a grounding electrode (a ground rod, the water pipe, or rebar in the foundation). No grounding electrode is connected to the service yet.

    250.50250.52
  • GEC Placement

    GEC must land at the service disconnect (not a downstream block).

    The main grounding connection has to land at the service disconnect, the first shutoff after the meter, not somewhere deeper in the system. It's currently attached to the wrong spot.

    250.50250.64
  • Service Disconnect Bond + GES

    The first OCPD-providing block downstream of the meter MUST carry both the N-G bond and the GES. Downstream blocks must NOT.

    Exactly one piece of equipment, the first shutoff after the meter, is where the neutral and ground get bonded together and the earth connection lands. That bonding is either missing here or happening at the wrong box.

    250.24(A)(5)250.50

NEC compliance

20 checks
  • Solar String Voltage

    Maximum DC voltage on a PV string within the inverter's maximum DC input voltage (NEC 690.7).

    Solar panels wired in a row add up their voltage, and on a cold sunny day that voltage spikes. This string's voltage can climb past what the inverter can safely handle: usually fixed by putting fewer panels in the string.

    690.7
  • Solar String Sizing

    Panel count per string must keep Voc (cold) ≤ inverter max and Vmp (hot) ≥ inverter MPPT minimum.

    A solar string needs enough panels to start the inverter on a hot day, but not so many that it over-volts on a cold day. This string is outside that safe window and the panel count needs adjusting.

    690.7690.8
  • MPPT Input Current Limit

    Per-MPPT current does not exceed the inverter's rated MPPT input current.

    Each input on the inverter can only take so much current. This input is being fed more than it's rated for, which means some of the solar production would be clipped or the input stressed.

    690.8
  • AC Branch Sizing (microinverter / AC module)

    Panel count per AC branch must satisfy NEC 705.13 / 690.8 continuous-current limit AND the microinverter manufacturer's max_units_per_branch[breakerSize] spec table.

    Microinverters chain together on a shared circuit, and there's a limit to how many fit on one branch before the wire is overloaded. This branch has too many panels on it and needs to be split.

    705.13690.8(A)(1)
  • MPPT Assignment Validity

    Every solar string is assigned to a valid MPPT on its inverter (not orphaned or over-stuffed).

    Each solar string has to be assigned to an actual input on the inverter. One of these strings isn't assigned to a valid input, so it's effectively floating.

  • Supply-Side Compliance

    Pro

    Supply-side interconnections meet NEC 705.11 conductor sizing + service disconnect requirements.

    When solar taps in ahead of the main breaker, special conductor and disconnect rules apply. This supply-side connection doesn't meet one of those requirements yet.

    705.11230.82(6)
  • Supply-Side Service Rating

    Pro

    Equipment connected on the supply side of the service (supply-side tap / direct meter connection) must be listed suitable for use as service equipment (SUSE).

    Equipment wired in ahead of the main breaker (like a supply-side tap disconnect, or a panel fed straight from the meter) has to be built and labeled for that job: 'suitable for use as service equipment.' This one isn't marked as such yet: confirm the label on the real equipment and flip the Service Rated toggle, or connect it after the main breaker instead.

    230.66705.11230.82(6)
  • Supply-Side Tap Length

    Pro

    Unprotected tap conductors on a supply-side interconnection respect NEC §705.11(C). Threshold depends on project scale: residential = 10 ft inside building, commercial = 16.5 ft (or 71 ft with cable limiters). Wires already sized to their downstream OCPD are skipped: they satisfy 705.11(C)(1)(b). The ceiling is an INSIDE-building limit: a conductor whose tap location is declared Outside (or Considered outside per §230.6) is exempt, and the §230.6 case gets an info note since that section is written for service conductors.

    When you tap solar in ahead of the main breaker, the unprotected stretch of wire before its disconnect has a strict length limit INSIDE the building. This run is too long for where it's installed: move the disconnect closer to the tap, or, if the wire actually runs outdoors, mark its tap location as outside in the conductor schedule and the limit no longer applies.

    705.11(C)230.6
  • Voltage / Phase Compatibility

    Connected blocks share compatible voltage + phase (no single-phase wired to three-phase, no 240V to 480V).

    Two pieces of connected equipment expect different voltages or phases (like plugging a 120V device into a 240V outlet). They can't be wired together as-is.

  • Breaker Pole / Phase Match

    Breaker pole count matches the phase configuration (1P for 120V, 2P for 240V split, 3P for 208/480V wye/delta).

    A breaker needs the right number of 'poles' for the voltage it's switching: single-pole for 120V, two-pole for 240V, three-pole for three-phase. This breaker's pole count doesn't match its circuit.

    240.15
  • Interconnection Compliance (705.12)

    Pro

    120% rule, sum rule, feed-through tap, and derate enforcement for load-side solar interconnections.

    There's a limit to how much solar and battery power you can backfeed into a panel before its busbar is overloaded (the '120% rule'). This design exceeds that limit: options are a bigger panel, a smaller main breaker, or a Power Control System.

    705.12(B)(2)705.12(B)(3)705.12(B)(5)
  • Power Control System (705.13)

    Pro

    PCS-controlled installations: combined source current must not exceed declared PCS limit, and a 705.13-listed host device must be present.

    A Power Control System is a smart device that actively limits how much combined power hits the busbar. Either the limit is set too high for the panel, or the listed device that's supposed to enforce it is missing from the design.

    705.13
  • PCS Conductor Sizing (750.30 / 215.3)

    Pro

    Conductors between the PCS host and the protected panel must be sized for PCS setpoint × 1.25 (continuous-load factor), and the OCPD must not exceed the PCS setpoint.

    The wires between the Power Control System and the panel it protects have to be sized for the limit the PCS enforces. The wire size or its breaker doesn't line up with that limit here.

    750.30120.7215.3240.4(B)
  • Backup Loads Panel Protection (705.12)

    Pro

    A MLO (main-lugs-only) backup panel downstream of a PCS host needs at least one of: (1) external inline OCPD ≤ panel rating, (2) PCS Panel Limits configured for the backup busbar, (3) total island-mode source capacity ≤ panel rating. The gateway internal main breaker does NOT protect the backup panel.

    A backup loads panel with no main breaker of its own needs something else to protect it during an outage. Right now nothing is guaranteeing the backup panel's busbar can't be overloaded: the gateway's internal breaker doesn't count.

    705.12(B)(3)(2)
  • Tesla PV-to-Powerwall Ratio

    Pro

    AC-coupled solar in the Tesla backup circuit ≤ 7.68 kW per Powerwall (10 kW per PW3 with Expansion). Excess must be routed line-side of the Gateway.

    Tesla limits how much solar can sit on the backup side of the Gateway per Powerwall. This design has more solar in the backup circuit than the batteries can handle, so some of it has to move to the grid side of the Gateway.

    Tesla Install Manual705.12(B)(3)705.11(C)
  • Line-Side Tap Target Validity

    Pro

    Line-side tap interconnection requires a panel with a line_tap port (main / meter-main) or an external service-entrance tap point. MLO panels have no line_tap port.

    A line-side tap needs a panel that actually has a tap point ahead of its main breaker. This panel is main-lugs-only and has no such tap point, so the connection can't land there.

    705.11(C)
  • Feeder Tap Conductor Rules

    Pro

    Load-side feeder tap conductors must meet a NEC 240.21(B) length tier: (B)(1) ≤10 ft (ampacity ≥ terminating OCPD), (B)(2) ≤25 ft (ampacity ≥ 1/3 feeder OCPD), or the special >25 ft tiers (B)(4)/(B)(5). With a power source on the feeder, 705.12(A)(3) raises the 1/3 basis to (feeder OCPD + Σ PV OCPDs). Errors on an undersized tap; warns on a >25 ft tap. A tap whose location is declared Outside (or Considered outside per §230.6) skips the length tiers and is checked against the (B)(5) CONDITIONS instead: it must terminate in a single OCPD, rated ≤ the conductor ampacity, at the point of entry; failing either is an error, since without that termination no 240.21(B) tier permits the run. Supply-side line taps (705.11) are excluded. See docs/NEC_240_21B_FEEDER_TAPS.md.

    A tap wire connects to a feeder without its own breaker at the tap, so the code limits how long it can be and how small it can be. Short taps (≤10 ft) must carry at least their end breaker; ≤25 ft taps must be at least a third of the feeder's breaker, and because solar adds a second source, that third is figured on the feeder breaker PLUS the solar breaker, so the tap wire often has to be a size or two bigger. A tap that runs OUTSIDE the building has no length limit at all, but only if it ends in one breaker or fuse, no bigger than the wire can carry, right where it enters the building, without that, the outside allowance doesn't exist. This tap doesn't meet its rule, so upsize the wire, add or resize the end breaker, or shorten/relocate the run.

    240.21(B)240.21(B)(5)705.12(A)(3)230.6
  • Feedthrough Tap Conductor Protection

    Pro

    A load-side tap on a feedthrough FEEDER is governed by NEC 705.12(A) (Feeders and Feeder Taps), NOT the busbar 120% rule (B)(2) or busbar feed-through (B)(5). Acceptable when (A)(2)(a) feeder ampacity ≥ primary-source OCPD + 125% PV, OR (A)(2)(b) an OCPD ≤ feeder ampacity at the load-side connection (the downstream panel main). Warns when (b) is not met, MLO downstream panel, or a downstream main exceeding the feeder ampacity (the 310.12(B) 83% main feeder, no longer auto-qualifying post-tap), pointing to (a) as the alternative. A tap does NOT increase the feeder load; this is protection coordination, not overload.

    Solar tapped onto the feeder that feeds the downstream panel. The tap doesn't add load to that wire, but it does change which code rule applies: the downstream panel either needs its own main breaker no larger than the feeder can carry, or the feeder has to be big enough for its load plus the solar. Right now neither is confirmed: add a correctly-sized main on the downstream panel, or verify the feeder is large enough.

    705.12(A)310.12(B)
  • Dual Main Panels

    Pro

    Detect ambiguous service topologies where multiple panels could be the service disconnect (single-disconnect rule).

    The service can only have one main shutoff, but this layout has more than one panel that could be it. The drawing needs to make clear which single panel is the service disconnect.

    230.71
  • Inverter Output OCPD

    Every string inverter AC output is wired AND has an OCPD (breaker / fuse / PCS-controlled port) upstream: catches floating inverters when a combiner runs out of breaker slots.

    Every inverter's AC output needs both a wire and a breaker/fuse feeding into the system. This inverter is missing one: often because a combiner ran out of breaker slots and left it stranded.

    705.12240.21690.13

Service & topology

1 check
  • Kirchhoff Current Law

    Current into a node equals current out (no source receiving current, no load driving an output, combiner outputs sum branch inputs).

    The current going into a junction should equal the current coming out: power can't appear or vanish. The numbers don't balance here, which usually points to a mis-wired or mis-sized connection.

System topology

3 checks
  • Gateway Smart-Port Slot Capacity

    AC source count must not exceed the gateway's physical smart-port slot count. Excess sources require an AC combiner upstream or a sub-distribution panel.

    The gateway only has so many physical slots for power sources to plug into, and the design is trying to plug in more than it has. You'd need a combiner panel to merge some sources first, or a bigger gateway.

  • Unused Breaker Slots

    Multi-breaker hosts (gateway, smart panel, combiner) shouldn't draw breakers in physically-uninstalled slot positions. Auto-fix prunes unwired positional slots to match installed hardware.

    The panel is showing breakers in slots where nothing is actually wired. These phantom breakers should be removed so the drawing matches what gets installed.

  • Conduit Defaults Unresolved

    Wire created without a matching conduit-defaults rule: both conduitType + insulationType remain undefined. Pick values manually or extend the rules table.

    Every wire run needs a conduit type (the pipe it runs through) and a wire type. The system couldn't auto-pick them for this run, so they need to be chosen manually.

Connections & wiring

5 checks
  • Missing Connections

    Required connection points (utility input, main breaker, etc.) have wires landing on them.

    A required connection point (like the utility feed or the main breaker) doesn't have a wire landing on it. Something that needs to be hooked up isn't yet.

  • Half-Connected Pass-Throughs

    Pass-through devices (junction boxes, disconnects) have both input AND output wired.

    A pass-through device like a junction box or disconnect has a wire going in but nothing coming out (or vice versa). It needs to be wired through on both sides to actually carry power.

  • Orphaned Breakers

    Panel breakers have a downstream wire connected (no orphans drawn but not wired).

    A breaker is drawn in the panel but nothing is wired to it. Either wire something to it or remove it so the drawing reflects the real install.

  • Dangling Wire Endpoints

    Wires terminate at a known connection point on a block: not free-floating in space.

    A wire ends in empty space instead of landing on a real connection point. Both ends of every wire need to attach to actual equipment.

  • Connection Topology

    Wire topology is consistent (no upstream loops, no source-into-source connections).

    Something is wired in a way that doesn't make electrical sense: like a loop feeding itself, or two power sources wired directly into each other. The wiring path needs to be corrected.

Equipment configuration

4 checks
  • PV Array Set

    Solar panels have been set for the design (not left as the template placeholder).

    This design started from a template, and the solar panels shown are just the template's example: not your actual panels. Open Project Settings → Solar Equipment to pick the real panel model and count before this drawing goes anywhere official.

  • AC Module vs Separate MLPE

    An AC module has an integrated microinverter: the string must not also carry a separately selected MLPE device.

    An AC module already has its microinverter built into the panel, so adding a separate microinverter or optimizer to the same string is counting the same equipment twice. Pick one: the AC module on its own, or ordinary DC panels with the separate device.

  • Monitoring Equipment Compatibility

    Monitoring devices are compatible with the inverters/gateways they monitor.

    The monitoring device (the part that reports production to an app) has to be compatible with the inverter or gateway it's watching. This pairing isn't a supported combination.

  • Meter Socket Rating Set

    Every meter socket has a current rating set. Recipes may defer rating at creation; this check ensures it is resolved before planset signoff.

    The meter socket doesn't have an amperage rating set yet. It needs one before the plan set is finalized so the service size is documented.

    230.42230.79

Elevation & structural

1 check
  • Elevation Mounting & Clearances

    Wall-mounted equipment on the elevation pages: minimum mounting heights (AFF), manufacturer/NEC working clearances free of obstructions, no physically overlapping enclosures, operating handles within the 6'-7" max reach, and ESS kept 3 ft from doors/windows.

    The elevation drawing shows where equipment physically hangs on the wall, and inspectors check it against real-world rules: boxes can't overlap, shutoff handles must be reachable (no higher than 6'-7"), equipment needs its required breathing room, and batteries have to keep their distance from doors and windows. Something on the wall breaks one of those rules: drag it to a compliant spot.

    110.26(A)(2)240.24(A)404.8(A)NFPA 855

Looking up an NEC article?

The same 46 checks, indexed by the 39 NEC articles they enforce. Sub-parts are grouped under their base article; the exact citation stays on each check above.

NEC articleWhat we verifyChecks
110.26Elevation Mounting & Clearances1
120.7PCS Conductor Sizing (750.30 / 215.3)1
210.19Voltage Drop1
210.20OCPD vs Conductor Current1
215.2Voltage Drop1
215.3OCPD vs Conductor Current, PCS Conductor Sizing (750.30 / 215.3)2
230.6Supply-Side Tap Length, Feeder Tap Conductor Rules2
230.42Meter Socket Rating Set1
230.66Supply-Side Service Rating1
230.71Dual Main Panels1
230.79Meter Socket Rating Set1
230.82Supply-Side Compliance, Supply-Side Service Rating2
240.4OCPD vs Conductor Current, PCS Conductor Sizing (750.30 / 215.3)2
240.6OCPD Standard Sizes1
240.12OCPD Coordination1
240.15Breaker Pole / Phase Match1
240.21Unprotected Circuits, Feeder Tap Conductor Rules, Inverter Output OCPD3
240.24Elevation Mounting & Clearances1
250.24EGC Inclusion Policy, Service Disconnect Bond + GES2
250.50Grounding Electrode System Present, GEC Placement, Service Disconnect Bond + GES3
250.52Grounding Electrode System Present1
250.64GEC Placement1
250.66GEC Sizing1
250.122EGC Sizing1
250.142EGC Inclusion Policy1
310.12Feedthrough Tap Conductor Protection1
404.8Elevation Mounting & Clearances1
690.7Solar String Voltage, Solar String Sizing2
690.8Solar String Sizing, MPPT Input Current Limit, AC Branch Sizing (microinverter / AC module)3
690.13Inverter Output OCPD1
700.32OCPD Coordination1
705.11Supply-Side Compliance, Supply-Side Service Rating, Supply-Side Tap Length, Tesla PV-to-Powerwall Ratio, Line-Side Tap Target Validity5
705.12Interconnection Compliance (705.12), Backup Loads Panel Protection (705.12), Tesla PV-to-Powerwall Ratio, Feeder Tap Conductor Rules, Feedthrough Tap Conductor Protection, Inverter Output OCPD6
705.13AC Branch Sizing (microinverter / AC module), Power Control System (705.13)2
750.30PCS Conductor Sizing (750.30 / 215.3)1
ANSI C84.1 (Range A +5%)AC Interconnection Voltage Rise1
IEEE 1547-2018 (OV trip 1.10 p.u.)AC Interconnection Voltage Rise1
NFPA 855Elevation Mounting & Clearances1
Tesla Install ManualTesla PV-to-Powerwall Ratio1

FAQ

Design checks, answered straight.

What is a solar design check?

An automated review of your single-line diagram against the code rules an inspector will apply. Solar Design Lab runs 46 of them live as you design: overcurrent protection, conductor and voltage-drop math, grounding and bonding, interconnection limits, equipment configuration, and site conditions. Each finding tells you what is wrong, which NEC article it comes from, and in most cases fixes it for you.

When do the checks run?

Continuously, as you design. You do not submit anything or wait for a review queue. Place a piece of equipment or draw a wire and the affected checks re-run immediately, so problems surface while you are still holding the thought that caused them.

Does passing the checks guarantee my permit is approved?

No, and anyone promising that is selling something. Passing means your plan set is complete and code-correct on everything the engine can verify. Approval also depends on your design choices and your jurisdiction, which can ask for local documents no plan set covers. What the checks remove is the category of rejection that comes from a missed calculation or an omitted label.

Which findings can be fixed automatically?

The mechanical ones: rounding an overcurrent device to a real standard size, upsizing a conductor that fails its ampacity or voltage-drop target, adding a missing equipment grounding conductor, correcting a neutral-to-ground bond in the wrong enclosure. Judgment calls are never auto-applied. The engine flags those and explains the tradeoff so the decision stays yours.

Which NEC edition do the checks use?

You pick the code edition your jurisdiction has adopted, and the checks apply that cycle. This matters more than it used to: adoption is uneven across states, and a plan set citing the wrong cycle on its cover sheet can be rejected on that alone.

Do I need a paid plan to run design checks?

No. The core checks run on the free single-line editor with no account required. 13 of the deeper interconnection and service-rating checks are part of the paid tier, and they appear as locked findings so you can always see that something was flagged.

Run all 46 on your own design.

Draw a single-line diagram in your browser and watch the checks run as you go. No account needed to start.