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diy solar

diy solar

23kw roof mount system and other things

kennyb

Solar Enthusiast
Joined
Mar 14, 2023
Messages
222
Location
Canaderp
The time finally arrived. I've got all my supplies, the utility building is done enough for now. I can't put it off any longer. Winter is coming and I need power in the house to commission the heating system.

The pv system consists of 60 385w panels, mounted across 2 roofs. One at 180deg, the other at 160. The roofs are 12:12 standing seam. I utilized S5! clamps and racking from a Canadian company called "fastrack".

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Power from the each roof enter the building into their own combiner boxes, then exit the building into imo disconnects before power is sent 250ft down hill to the utility building. imo disconnects are placed before entry into the building. Inside 60kwh of gsl lithium and 2x lux 12k and 1 old Schneider xw+ (so I can keep my existing Ac coupled arrays)will be stored. There's still loads of electrical work to do, but I can get to that when the arrays are finished.
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I'm 5 days in to the roof install and have one roof racked and 10 of 30 panels mounted and wired. With any luck I'll have the other 20 up by the end of next weekend.

This is definitely not my happy place, but I'm making steady progress. The pump jack scaffolding really is making the install possible. To assist with getting the panels up to the scaffold stage, I made a make-shift crane out of my sxs winch. There was no way I could lift the panels up the ladder safely.
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I'll try to keep this updated as I move along.
 
I don't know how to do it but I would advise you to build it at ground level and slap it on the roof.
Do two or three panels/day while at your best physical and mental shape.
Make sure you strap yourself down. All it takes is tripping over something while up there.
Keep all leads outside from underneath, tie them together if necessary.
Rehearse everything on the ground so there's less of a need to fix things up there.
 
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You need a second plank on the back of the pump jacks so you can lean the panels on the bottom plank against the top plank. You can fit probably 10+ panels on at a time.

I sure hope you have help pumping up.

This is how i got the plywood up when I built my garage.

ld7Wwaw.jpg
 
The time finally arrived. I've got all my supplies, the utility building is done enough for now. I can't put it off any longer. Winter is coming and I need power in the house to commission the heating system.

The pv system consists of 60 385w panels, mounted across 2 roofs. One at 180deg, the other at 160. The roofs are 12:12 standing seam. I utilized S5! clamps and racking from a Canadian company called "fastrack".

View attachment 252045
View attachment 252050
Power from the each roof enter the building into their own combiner boxes, then exit the building into imo disconnects before power is sent 250ft down hill to the utility building. imo disconnects are placed before entry into the building. Inside 60kwh of gsl lithium and 2x lux 12k and 1 old Schneider xw+ (so I can keep my existing Ac coupled arrays)will be stored. There's still loads of electrical work to do, but I can get to that when the arrays are finished.
View attachment 252046

View attachment 252049
I'm 5 days in to the roof install and have one roof racked and 10 of 30 panels mounted and wired. With any luck I'll have the other 20 up by the end of next weekend.

This is definitely not my happy place, but I'm making steady progress. The pump jack scaffolding really is making the install possible. To assist with getting the panels up to the scaffold stage, I made a make-shift crane out of my sxs winch. There was no way I could lift the panels up the ladder safely.
View attachment 252048

I'll try to keep this updated as I move along.
That’s a really steep roof, be careful up there!
 
You need a second plank on the back of the pump jacks so you can lean the panels on the bottom plank against the top plank. You can fit probably 10+ panels on at a time.

I sure hope you have help pumping up.

This is how i got the plywood up when I built my garage.

ld7Wwaw.jpg

Just an army of one since framing (I had my dad and wife then).

I was a muppet and didn't think about the heat pumps so I can't lower the platform to ground level. The hoist works really well though. So I'm using it and just climbing up and down the ladder

I need to get another stage for the siding install. I usually use my ladder or an lvl and lean up materials against it. That's how I covered the entire building in the wrb, installed the rigid insulation and installed the strapping.
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Slow week. Kid was sick (and got everyone else sick) and then had a pd day.

11 of 30 up. The next 4 days look nice. Snow equals are forecasted for the end of the week. Pressure is on.
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Wow, the roof looks great, that’s going to be a nice system. How are you planning to send the power down the hill? Buried conduit?
 
Seriously nice home in a fabulous location.
The amount of work you are doing on your own is amazing, I just finished building a single story home with an easy roof here in Florida and it was far more work than I was willing to take on so I subbed out quite a bit of work.
 
Wow, the roof looks great, that’s going to be a nice system. How are you planning to send the power down the hill? Buried conduit?
I've already run 2 parallel runs of #12, 6 conductor Teck 90 (weather proof, armoured, direct burial cable).

Anything else wasn't going to work with the exposed bald rock sections.
 
Seriously nice home in a fabulous location.
The amount of work you are doing on your own is amazing, I just finished building a single story home with an easy roof here in Florida and it was far more work than I was willing to take on so I subbed out quite a bit of work.
Thanks. I tried to sub things out, but kept getting the rich cottagers quotes. Can't afford that nonsense.

Like duct work for 70k. Smh.
 
Yeah I got a quote of around 40 Grand for the HVAC system, I DIYed everything and still had change out of 10 grand.
I did similar. I found a retired HVAC tech. He sold me dozens of full sheets of galv. I put the ducts into sheet metal cad, made patterns, plotted, transfered and then bent all the ducts. It was a shame to cover it all.


Today's annoyance is stainless steel galling. Either I'm a complete moron, or these ss mid clamp fasteners are the worst fasteners ever machined - I can visually see the rough surface finish.

I've lost 10% to galling and now I'm 2 short to finish.
I followed the torque requirements of 20nm, but these seize so easily, not even close to torque and if you try to remove, they're toast.
 
I use copper grease on stainless steel fasteners to reduce galling. Polish the threads if they are rough. Nickel grease works too.
 
Today's annoyance is stainless steel galling.
That’s the worst! I totally feel your pain.
I ended up using bolt cutters to remove some of the galled bolts I had rushed.
They say go really slowly and pause frequently to prevent it. Didn’t really help.

I ended up using some nickel anti-seize, but that stuff is so messy it was almost as bad as the galling.

Beautiful work!
 

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