diy solar

diy solar

My Off-Grid panels going up real soon.

jasonhc73

Cat herder, and dog toy tosser.
Joined
Oct 1, 2019
Messages
1,921
Location
Wichita, Kansas
The parts:
(and links)
  • 295w used solar panels (I've seen 248w from them already! They are polycrystalline, big and heavy, way overbuilt for residential use.)
  • Superstrut
    • Lowes
    • Threaded rod hangers (Sammys 3/8-16 for wood)
      • Ebay
        • Sammys 8113910 - #14 Nut Driver
        • Ebay
    • Bolts to hold the Superstrut to the Threaded Rod hangers
    • 3/8 washers 316SS for bolts to hold the Superstrut to the Sammy
    • X-Large Rubber Fender washers (Helps seal the roof and a gap between the steel and the aluminum)
    • Bolts to hold the panels to the Superstrut
    • Fender washers to hold panels
    • Spring Nuts for Superstrut (so the bolt holding the panels to the strut have something to tighten with)
  • 8AWG outdoor PV cable for the panels. (10 would work fine, but it's cheap so why not?)
  • PVC Box for the circuit breakers to live in
  • Roof Sealant
So far I don't have a conduit for the wires from the roof to the inverter. I am not sure I am going to go that route yet, but I probably will in the end. I do have outdoor-rated high-quality 8AWG from Missouri Wind and Solar.

I made a layout this afternoon on the roof with a cardboard template. I will have about a 1-foot gap between two rows of 5 and a row of 2.

I plan to have 2 strings of 3s X 2p (12 total panels, 3.5 kWp), 120VDC will work with my 60-115V MPPTs. (MPP Solar LV5048, x2, 4 total MPPTs, 4000w capable each/16kW of possibility!)

I have 6.2 kWp of SolarEdge grid-tied. That I waisted an enormous amount of money on. Had I done this "DIY" I would have saved a great deal of money, just to blow on more battery banks. ?

 
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J, one thing i can say is that it might save money to use ironridge or equivalent rail amd accessories to mount. Unistrut and other similar materis can run 10$ a foot or 80$/ 8 foot stick amd ironridge rail, xr100 (mid size, strong) 35$ 14' in black of you like.

If you are not using flashed roof attachments. (9$ each) eurethane sealants under L feet work well enough for diy. It was done for decades....

Saves money, works well, looks great.
 
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Superstrut is only $1.40-$2.20 a foot. $20 for 10 foot stick. I paid $140, for 8 10 footers at Lowe's.

I priced out the aluminum "Solar" mount way and was looking at $650 to $800 every time I added it up. This way is just under $300.

The "Caulk" seal is the only thing left to aquire. I am thinking maybe
Henry 10.1 oz. 209XR Extreme Rubberized Wet Patch Roof Leak Repair. (home depot)
 

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Look around and see if electrical or construction scrap yards have any.
There is a place that sells strut etc for just over scrap price... waaaay cheaper if perfection isnt needed...
 
Jason,

Why is your dog looking at me like that?

I think you win the award for most different pictures! ?
 
Holy Cow,
Fasteners Inc did wicked fast on the mail.

96002 --> 67217 priority 2-Day. It's about a 30lb box.

I have everything now, except for the goop sealing stuff.
 

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Step 487 of 12,000. Done!

IMG_20200304_165641617.jpg IMG_20200304_165644983.jpg

These are the sammy's (3/8-16) with 2-inch washers and roofing goop.
The superstruts get bolted to the sammy's, then the panels rest on the superstrut, held in place by bolts and 2-inch washers.
 
Step 487 of 12,000. Done!

View attachment 8540 View attachment 8539

These are the sammy's (3/8-16) with 2-inch washers and roofing goop.
The superstruts get bolted to the sammy's, then the panels rest on the superstrut, held in place by bolts and 2-inch washers.
Its an emotional rollercoaster ride. Everytime i start one like captain Ahab....... i wind up in a fetal position shaking my head no by lunchtime..... then im all good!
 
We're probably close to neighbors! Missouri Wind and Solar in Seymour, right?

We're on the same path. My husband had a slightly apoplectic fit at 25 a stick for unistrut though. Like $400 for what we need. So....we're doing it differently.
 
We're probably close to neighbors! Missouri Wind and Solar in Seymour, right?

We're on the same path. My husband had a slightly apoplectic fit at 25 a stick for unistrut though. Like $400 for what we need. So....we're doing it differently.
Yep in Seymour(I'm in Wichita, KS)... My choice to go unistrut/superstrut instead of "aluminum" is pure ease of access and shipping. 10ft sticks in a pickup from lowes/hd/menards vs 17ft and massive shipping fee from any of the online shops, and all proprietary. Plus there are 1000's of options available that bolt right to the Unistrut stuff for making and hanging and designing other things. I considered the 80/20 but it's $30 for 8-foot bars(through Grainger). That's $300 just in bars for this project.
 
So not really neighbors, but close enough! We're SC Mozarks.

I'm going to watch your progress! Thanks for letting me do so!
 
Finding a decent Round2It sometimes is harder than you can imagine.
Yesterday I spent 3/4 of the day figuring out how to get my panels up my sled and ladder. My wench crapped out on me, so I had to get some double pulleys and hand lift them up the sled.

Step 8439 of 12,000 complete!

IMG_20200330_115414709.jpg IMG_20200330_115411476.jpg IMG_20200330_115400873_HDR.jpg
6 panels 3S2P
IMG_20200330_115314401.jpg
6 panel 2S 3P
IMG_20200330_115303260.jpg

Each MPP Solar has two 4000W MPPT's.
After I put the other 6 panels on the roof, I will put them in 2S 3P configuration also.

Also yesterday, I witnessed my used panels with 282 watts! STC measured/rated for 295!
 
Finding a decent Round2It sometimes is harder than you can imagine.
Yesterday I spent 3/4 of the day figuring out how to get my panels up my sled and ladder. My wench crapped out on me, so I had to get some double pulleys and hand lift them up the sled.

Step 8439 of 12,000 complete!

View attachment 9933 View attachment 9934 View attachment 9935
6 panels 3S2P
View attachment 9936
6 panel 2S 3P
View attachment 9937

Each MPP Solar has two 4000W MPPT's.
After I put the other 6 panels on the roof, I will put them in 2S 3P configuration also.

Also yesterday, I witnessed my used panels with 282 watts! STC measured/rated for 295!
Yes, i love this part. When the wires are sized appropriately and good modules are used, approching and even exceeding nameplate rating is not the rare unicorn people assume it is!
 
Step 9369 of 12000. SO CLOSE...

I measured wrong or cut wrong, what ever I need 168 (4x42) more inches of super strut. Somehow I had it in the cheese head that I had 12 foot long Superstrut, but nope 10 feet.

How to bolt on the ends:
IMG_20200401_171315428.jpg
IMG_20200401_171326345.jpg
 
Sorry your "wench" crapped out on you -- mine's been satisfying me for years :) On the other hand I have gone through plenty of winches in my time.
 
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