Solar Installation – Flying High and Far Away
The title reflects the unique install. The roof layout for the panels shows the roof vent and skylight. In addition there are the evil shadow producing A/Cs and ladder.
Three 250W Cynergy polycrystalline panels (65” x 39”) were installed on the roof. The panels are mounted 7.5” above the roof (hence the Flying High title :B) which virtually eliminates A/C shadows, clears the skylight and fan vent, provides better panel cooling and allows for easy under panel roof cleaning.
Installation started
6” x 1.5” angled aluminum secures the panel support with VHB tape and 3 #10 screws. The inside (near the center of the roof) support riser is 6” x 1.5” x 1/8” flat stock and is connected to the panels with angled aluminum. The outside (near the edge of the roof) support riser length was adjusted to provide a 4 degree slant on the panels for water runoff. The screws, bolts nylon locknuts and washers are stainless.
The outside riser is adjusted for a 4 degree slope for water runoff
The panels are wired in series with 10 gauge UV resistant wire. The panel wiring length is 42’ plus the Cynergy panel wires which add up to 19’ or 61’ total. The wires are secured to the roof with Dicor self leveling calk. Gorilla tape was used to initially secure the wires for several days while the Dicor firmed up. And Dicor is used to seal the wires as they pass through the roof. The wires on the lower right corner are not part of the solar project.
Wiring and Dicor
Raising the panels also allows clearance for the Fantastic roof vent. The vent is designed to stop opening when it contacts something like a tree limb and in this case a solar panel while the fan continues to run. A rubber pad is attached to the vent at the contact point with a piece of VHB tape.
Open fan vent
A rising or setting sun will only cast a shadow from the A/Cs when the sun is less than 10.6 degrees elevation and the rig orientation aligns the panel and A/C with the sun azimuth. As a result there is very little power loss if any due to shadows for the day and hence no need to raise the panels further. The picture shows the sun angle.
Here’s the controller, DC CB battery switch and A/C disconnect switch for the panel wiring. The A/C switch was cheap but not otherwise the best choice. Perhaps there will be a future upgrade to this switch and some slack was left in the wiring for this purpose. The right side controller wires are for the battery temperature, battery voltage sense, remote meter and CAT 5 crossover cable for the PC
Controller and switches
The Morningstar MPPT 60 controller is located 3’ from the inverter and uses 4 gauge wires to the inverter DC terminals. The inverter is located 20’ (hence the Far Away title :B) from the batteries and uses 4/O gauge wire.
The 4 ga wire is for the controller and the 4/O ga wire is for the batteries
The batteries are 4x6V AGM at 440AH and the temperature probe is located on the upper right battery post
5 of the small wires are for the battery monitor and shunt and the other 2 are for the solar controller battery voltage sense.
The panel disconnect switch must be off befoe the full battery disconnect switch is turned off as there is a recent Morningstar update indicating that the MPPT 60 controller can be damaged if the battery connection is removed while the controller is charging. And the battery switch must be connected before the panel switch.
The controller remote panel is located above the TV along with the battery monitor, Progressive Industries power protector remote, Wilson inside cell panel antenna, satellite receiver and satellite dish controller.
Finished panel installation
Cost: Panels $600, controller and remote $595, electrical and wiring $147, hardware $105 for $1447 and results in a cost of $1.93/watt (October 2014 prices) and yields 14.2 watts/sq ft of roof space. The prices include tax and S&H if applicable.
Wiring loss: Panels to controller 0.5V, 0.6% and controller to batteries 0.2V, 1.4%.
Three 250W Cynergy polycrystalline panels (65” x 39”) were installed on the roof. The panels are mounted 7.5” above the roof (hence the Flying High title :B) which virtually eliminates A/C shadows, clears the skylight and fan vent, provides better panel cooling and allows for easy under panel roof cleaning.
Installation started
6” x 1.5” angled aluminum secures the panel support with VHB tape and 3 #10 screws. The inside (near the center of the roof) support riser is 6” x 1.5” x 1/8” flat stock and is connected to the panels with angled aluminum. The outside (near the edge of the roof) support riser length was adjusted to provide a 4 degree slant on the panels for water runoff. The screws, bolts nylon locknuts and washers are stainless.
The outside riser is adjusted for a 4 degree slope for water runoff
The panels are wired in series with 10 gauge UV resistant wire. The panel wiring length is 42’ plus the Cynergy panel wires which add up to 19’ or 61’ total. The wires are secured to the roof with Dicor self leveling calk. Gorilla tape was used to initially secure the wires for several days while the Dicor firmed up. And Dicor is used to seal the wires as they pass through the roof. The wires on the lower right corner are not part of the solar project.
Wiring and Dicor
Raising the panels also allows clearance for the Fantastic roof vent. The vent is designed to stop opening when it contacts something like a tree limb and in this case a solar panel while the fan continues to run. A rubber pad is attached to the vent at the contact point with a piece of VHB tape.
Open fan vent
A rising or setting sun will only cast a shadow from the A/Cs when the sun is less than 10.6 degrees elevation and the rig orientation aligns the panel and A/C with the sun azimuth. As a result there is very little power loss if any due to shadows for the day and hence no need to raise the panels further. The picture shows the sun angle.
Here’s the controller, DC CB battery switch and A/C disconnect switch for the panel wiring. The A/C switch was cheap but not otherwise the best choice. Perhaps there will be a future upgrade to this switch and some slack was left in the wiring for this purpose. The right side controller wires are for the battery temperature, battery voltage sense, remote meter and CAT 5 crossover cable for the PC
Controller and switches
The Morningstar MPPT 60 controller is located 3’ from the inverter and uses 4 gauge wires to the inverter DC terminals. The inverter is located 20’ (hence the Far Away title :B) from the batteries and uses 4/O gauge wire.
The 4 ga wire is for the controller and the 4/O ga wire is for the batteries
The batteries are 4x6V AGM at 440AH and the temperature probe is located on the upper right battery post
5 of the small wires are for the battery monitor and shunt and the other 2 are for the solar controller battery voltage sense.
The panel disconnect switch must be off befoe the full battery disconnect switch is turned off as there is a recent Morningstar update indicating that the MPPT 60 controller can be damaged if the battery connection is removed while the controller is charging. And the battery switch must be connected before the panel switch.
The controller remote panel is located above the TV along with the battery monitor, Progressive Industries power protector remote, Wilson inside cell panel antenna, satellite receiver and satellite dish controller.
Finished panel installation
Cost: Panels $600, controller and remote $595, electrical and wiring $147, hardware $105 for $1447 and results in a cost of $1.93/watt (October 2014 prices) and yields 14.2 watts/sq ft of roof space. The prices include tax and S&H if applicable.
Wiring loss: Panels to controller 0.5V, 0.6% and controller to batteries 0.2V, 1.4%.
