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Phases - Solar System

It was an EASY decision to add a photovoltaic solar system to our house. Not only is at an amazingly wonderful thing to do for the planet, to generate your own energy, but with the financial benefits of energy generation and generous rebates offered by the city of Glendale it really makes sense.

After bidding to Solar Contractors we realized that we could save $10,000 by buying the parts from an online supplier and by installing it ourselves. We bought a system from Solatron technologies which should generate the majoirity of our annual electric needs and includes a whole-house battery backup for power outages. Pretty Groovy!

The process

1) Analyze the financials . . . After some quality time with my electric bill and some Excel magic - It makes sense. Let's do it!

2) Choose a system. Done. Click here for the system description from the Solatron website.

3) Apply to reserve solar system rebates from the city of Glendale. Done.

4) Get a building permit from the city. Done. I created 3-D models of the system to ease the permitting process. Click here for a PDF file of the submittal documents, including models, engineering info and system details.

5) Order system. Done

6) Install blocks on roof rafters for attaching the standoffs that the rack sits on. Done.

7) Install rack standoffs on roof deck before roofing material is put down. Done

8) Install the Inverter and battery backup system. Done

9) After roofer has finished putting on the roof and putting on the flashing around the standoffs - Install the rails. Done

10) Install the panels. Done

11) Wire it all up - Elecrician required. Done

12) install the PV - Utility grid shut off switch. Done

13) Install Warning Signs. Done

14) Have it inspected (rough). Done

15) Pass final inspection for the garage.

15) Hook it up to the utility grid and start generating electricity! We can't wait.

Following, some highlight pictures | Next Phase: Chimney


Look at all of the sunshine on those southern rafters. that's where the system is going on our new garage.

3 rows of blocks are installed to attach the racking standoffs.

Standoffs are installed prior to roofing

The 3 rails will attach to the top of these standoffs and the panels will slide into the rail. (2 rows of 9 panels)

Two giant lag bolts are driven into the underlying block

The inverter and backup battery array get installed next to the main electrical panel. This unit comes pre wired so all that needs to be done is attach the panels to it and attach it to the main and sub panels.

After the roof was done I installed the "L-feet" and caulked the flashing.


Then it was time to put up the rails
 

Then the panels arrived :-)

Next came wiring the batteries
 

and preping the PS1 with PV array combiner breakers etc.

FINALLY. . .

it was time for the big solar panel install

 

Day 1) Solar panels were first covered with cardboard (to keep them from generating electricity while being installed).

The aluminum coating on the panel and the rails was scraped off at the grounding point
 

and the ground lug was installed with anti oxidant paste and all stainless fittings

This special copper grounding lug was hard to get, it's slightly different from the standard one which looks just the same, and costs twice as much (of course!)
  

The first row of the array is put up. Everything fit perfectly!

Serge and I did the install using all water tight fittings and junction boxes. The ground wire (coiled behind Serge) attaches to every panel and to each rail.
 

By the end of the day we were all ready to install the wire and put up the next row.
 

Day 2) Serge and I got the 2nd row of panels up and the wiring ready to pull from the roof.

Each panel's wires come into the watertight box from the flex line behind it.
 

Day 3) Serge and I worked on the solar install a bit more, running all of the conduit from the roof to the inverter.

Down the fascia, through the boxed gable, through some rafters down a rafter bay, out a hole and down to the inverter box.
 
 


Day 4) Serge and I did the final solar wiring connections. This was a difficult pull of 12 #10AWG wires and 1 #6AWG ground wire all together through a 1" metal conduit with 3 elbows, a bend and a junction box. New all there is left to do is connect the AC.

I used a multimeter to double check that the wiring was all done correctly from each array. (18 panels in 6 strings of 3 panels)

The battery charge controller (above) shows the charge from the batteries and voltage coming down from the panels. Until the AC is connected it will not show any watts generated,

 

The AC shut off switch that the City requires so they can shut off the system from the utility grid.
 

Required warning signs