Just thought I’d post this for the convenience of those folks who might attend my seminars this year, and would like to review them at their leisure from home. Even if you don’t attend the fair, there’s some pretty good info in this presentation for anyone considering doing PV Solar as a DIY project. The rest of my blog is filled with lots of detailed photos and text from solar projects of all sizes and equipment types.
Had a small problem with an SMA Sunny Island grid backup inverter (6KW). After sending SMA the Smart Card data, they promptly sent out a replacement and even included return shipping! Back up and running and customer is a happy camper once again. Based on this event, I would highly recommend you look at the SMA Sunny Island if you’re planning a Grid backup or even OFF-grid system! Sorry, I forgot my camera this trip!
Missed this photo on the first part of this adventure. The owner had materials on hand, and made the posts of Steel L channel, the beams from Steel S-channel, and the barn support brackets from 2 inch steel L material. The owner (George) is a VERY resourceful fellow – some might call him a scrounger, but I call him SMART! I passed along a great vendor deal on the solar panels and he purchased them direct. The BOS (balance of system) materials was purchased through Cinci Home Solar at great pricing, bringing the whole project in at about $3/watt, and this includes the battery bank and backup power inverters in addition to the Enphase micro-inverters behind each panel. The work was spread over 4 full days, with the helper crew varying from 1 to 3 guys and myself. Plenty of manpower to get this rather large project done in a timely fashion. Winter is really variable in Cincinnati, and whenever the weather was predicted to be above 40 and sunny, George called and we got the job done. Fortunately, this job was a quick drive from my home, and it wasn’t a problem. Normally, these 3 or 4 days would have been all condensed into one extended visit! I aim to please, whenever possible…
After we finished the 32 panel array, George saw that some minor grading of the ground near the bottom would allow plenty of room for 2 more rows! A week later he called me and said “Hey Joe, come on out and lets get these 2 rows installed – tomorrow’s weather looks great. So we did! When I ordered the extra components, we also added 8 more rails – one under each of the 8 columns of the upper 4 rows. You can see them mid-panel in the picture to the right. This provided the extra strength and rigidity that the span required for both wind and snow loading. Splicing the extra rails that extend to the newly installed lower beam also provided a counterbalance to the free span above.
The two missing panels at the lower left were intentionally left off because of a stone access road to the hay barn that George didn’t want to move.
This is what the backside looks like after everything is in place. After the rails were set, the Enphase M215 Micro-inverters were mounted. Then the #6 bare copper ground wire was run in series to each inverter. We grounded BOTH ends of the #6 copper, just because we could. Next came the Enphase TRUNK Cable, mounted with stainless steel clips to the rails. Then the panels were added, the micros were plugged in to the trunk cable and the panel leads connected to the micros. One end of the trunk cable is sealed with a weather tight cap, and the other goes to a weatherproof junction box (white) to transition to standard exterior rated 12-3 with ground romex. The romex connects to a breaker box with a 20 amp 2 pole breaker for each string of 16 and 1 string of 14 panels. Then, the entire array is nicely dressed using tie wraps so that all the wiring is suspended between the panels and the bottom of the rails to keep it from whipping in the wind or getting snagged by anything.
Here’s the power panel. Public Utility Commission in Ohio says any array over 6Kw must be metered by a UTILITY GRADE meter. Got one on Ebay for $35. Breaker box on left contains the 3 solar breakers. That feeds through the meter to the master breaker box on the right. Master breaker box connects to the utility grid via a buried conduit over to the other barn that had power in it already. Below the utility grade meter is the Enphase ENVOY monitoring unit that ties all this to the internet so George can watch things from his home computer. He can share a link with his friends as well. I’ll post this link soon as I get it from George! The Utility voltage here is rather high – close to the limits for most inverters, at 254Vac. This causes a few of the inverters to occasionally shut down (to protect themselves). I’ll be looking into this further on my next visit to see how we might correct this…
Here’s the finished array. Still need to trim the excess rail length at the bottoms. If you look close, you might just spot some mis-alignment within the array. George got 2 pallets of panels. Same part number, same vendor, but one pallet was 1/2 inch shorter on the long side (out of spec…). We didn’t catch this till 5 were mounted in the top row. George, being a prudent and thrifty fellow, called the panel supplier and negotiated a compromise that didn’t require a return of the panels. The size only affects the esthetics slightly, and a cost reduction is pending! The Enphase ENVOY normally communicates over the power lines, but there’s a half mile of them back to the house and that’s too far for it to work, so I added an Engenius EOC-1650 at the house as an access point, and atop the array as a client/bridge. It works great – with 100% signal integrity, and also provides WIFI to his customers and visitors! The EOC-1650 is that little white gadget at the top right of the array.
I went to the GEO (Green Energy Ohio) EV Seminar at the IBEW Training Center on Cincinnati’s West side yesterday and it was a relaxed, fun time. I got to drive the worlds 1st and only 100% electric Jeep Cherokee as well as several different Chevy Volts! Several speakers gave great presentations and there was a great deal to absorb in a short time. I did meet the admin for the EV program at the center, and I made the decision right on the spot to sign up for the fall class in EV Technology and to get my EV Certification by the end of this year! I’m already NABCEP certified for PV Solar installation and Technical Sales, and the electric car market is a good BLEND with solar, so I feel this is a great direction to grow in!
If this keeps up, I’m sure to generate 6 maybe 7 SRECs by the end of the year. Not bad for a DIY Solar Panel installation accomplished in less than 2 days by just ONE man! You can do it to, with my help! Just give me a call!! The best part of all is that the system will pay for itself in 5 years OR LESS, and if electric costs rise, the payback gets even better. After 5 years, the positive cash flows add up significantly and after 25 years, the system will have generated in excess of $30,000 in positive cash flow! I’m not sure if there are any investments in the market today that can promise that kind of return with the security of a DIY Solar Installation firmly fastened to your property!!