Keep it simple, solar: Advice and products to streamline your next rooftop install

Keep part counts low

solar roof hook

The Low Profile QuickBOLT with Microflashing from SolarRoofHook can be installed in less than 60 seconds, and the key is its Microflashing technology, which is installed on top of the shingles and eliminates the need to pry apart shingles and shove oversized aluminum flashing underneath.

“We would like to see installers move away from the old-school aluminum flashing method and replace that with Microflashing technology,” said Samantha Dalton, marketing manager for SolarRoofHook. “Using Microflashing reduces installers risk too. When installers are forced to separate shingles to install aluminum flashing, they often must remove nails from the roof. This leaves open penetrations in the roof, as well as leads them to risk voiding the roofing warranty and breaking code. Microflashing doesn’t pose those same risks and bonds with the roofing material to create a watertight seal.”

Quick Mount debuts new full rooftop rail system

 Quick Mount QRail

Quick Mount PV is simplifying your supply chain with QRail, its new rooftop racking system featuring patented QClick and QSplice technologies that simplify and speed installation. QRail combines with Quick Mount PV’s waterproof mounts to create a complete, fully-integrated racking and mounting solution for installing solar PV modules on any roof.

The patented QClick technology enables module clamps to easily click into the rail channel and remain in an upright position, ready to accept the module. QRail’s QSplice is the fastest, most efficient splice in the industry — a tool-free, bonded, fully-structural splice that installs in seconds with no extra hardware required.
Electrical bonding is fully integrated into every system component. All electrical bonds are created when the components are installed and tightened down. QRail is fully code compliant, certified to UL 2703, and backed by a 25-year warranty.

Pre-assembly

Magerack,

As a best practice, Jason Xie, president of Magerack, recommends assembling components on the ground as much as possible and avoiding assembling tiny components such as rubber washers on the roof.

For example, Magerack solar mounting components don’t contain any rubber components and all components are pre-assembled out of box. Magerack roof attachment doesn’t need any rubber washer and has no tiny components except pre-assembled fasteners. The two major components of MageMount MageMount II Rail-less Solar Mounting System, module connector and module brackets, can be assembled to the solar module on the ground before moving them on the roof. Module connectors are used to connect and secure two adjacent solar modules along the same row or between two rows. Those connectors and the roof attachments can be attached anywhere along the module edge where they are needed the most.

Look to kits

Unirac’s SunFrame Microrail

Consider systems where only a single tool is required for installation. Take Unirac’s SunFrame Microrail or the new Pro Series SM for example. Parts come pre-assembled out of the box making for a quick and easy install on the roof. There is no need to fumble with loose parts and pieces. Parts can be pulled from the box and can be put straight to use.

“One tool installation saves time on the roof, eliminating the chance of dropping tools while changing sockets,” says Anthony Romero, lead trainer for Unirac.

The SM Pro Series features module agnostic mid and end clamps. The end clamps secure the module while staying beneath the module. Arrays look very clean and appealing without any rail or hardware protruding. The mid clamps come pre-assembled and are self-standing. They also come coated with anti-seize to prevent galling and breaking stainless steel bolts. Unirac’s FlashKit Pro comes in a pack of 10 with flashing, L-Feet, T-bolts and lag bolts in one convenient box. Having everything in one package helps cut down on the amount of packaging needed on the roof. They are the easiest flashing kit to count, kit and carry to the roof.

SKU reduction

SunRunner 4 clip

The SunRunner 4 clip from Heyco was developed to reduce the number of SKUs for an installer. For those using a mix of SolarEdge and Enphase, this clip will handle both types of cable. The SunRunner 4 clips directly onto the PV module frame and holds up to four SolarEdge cables or up to three Enphase Q cables comfortably. The SunRunner 4 takes the guesswork out of ordering the correct clip as it holds both types of cable. Heyco also manufactures top rail clips with the exact same clip design as its SunRunner 4 for top racking manufacturers like Unirac, IronRidge, and Everest. This universal design allows the clips to be used on a wider range of installations and reduce the number of SKUs (and headaches) for installers. Heyco also offers a series of nylon UVX clips which qualify for its 20-year warranty and are generally 20 percent less expensive than their stainless steel equivalents.

— Solar Builder magazine

Heyco introduces four new cable tie products

Heyco has recently added multiple new products to its already extensive line of Cable Ties including Nylon 12, Blind Mount, Releasable, and HEYBite Cable Ties. Let’s meet the newbies.

Heyco cable ties

Heyco Nylon 12 Cable Ties are weather/UV resistant and suitable for high moisture, corrosive (zinc chloride and dilute acids) and low temperature indoor or outdoor applications. These ties are available in various lengths to accommodate a variety of different bundle sizes ranging from 1.44″ all the way up to 4.00″ bundles and the tensile strengths range from 40lbs all the way up to 100lbs.

Heyco blind mount cable tie

Heyco Blind Mount Cable Ties have a low insertion force with high pull out retention capabilities and can be mounted in either a through hold or a blind hole of proper depth. Due to the blind mount being assembled to the cable tie, no additional components are required.

Heyco releasable cable tie

Heyco Releasable Cable Ties have a locking mechanism that can be released so that wires can be added or removed from the bundle without cutting or otherwise damaging the cable tie.

Heybites

The HEYBite Clip mounts easily to frames and panel edges without the need for mounting holes or adhesives. The metal locking teeth bite easily into frames and panel edges, yet provide high removal resistance. HEYBites’ two piece assembly easily adjusts to various bundle diameters.

— Solar Builder magazine

The Ultimate SPI Showcase: Here’s what to see at Solar Power International 2017

Big leap for microinverters

APsystems SPI

APsystems will unveil the YC600, a dual-module, smart grid and Rule 21 compliant microinverter at SPI in Las Vegas. A groundbreaking design in microinverter technology, the YC600 will offer the highest peak output power, faster transmission speed and more modules allowed per string than comparable microinverters. A wider MPPT voltage range will result in a greater energy harvest for homeowners.

You’ll want to get the full scoop at booth 1745.

Streamlined Shutdown

Fronius

Fronius is launching a new generation of its Rapid Shutdown Box, which the company says will be the most convenient solution for NEC 2014 (690.12) and NEC 2017 compliance, while enhancing overall rooftop and firefighter safety. The new generation includes two versions: the Fronius Rapid Shutdown Box Duo and Quattro.
“Based on customer feedback, we implemented many improvements into this new generation of our Rapid Shutdown Box,” says Michael Mendik, head of solution management at Fronius USA.

Directly connected to the inverter through the same conduit as the DC homeruns and powered by the array, the Fronius solution minimizes the number of components and eliminates the need for an external power supply. The low-profile design and the multiple mounting options allow for installation underneath the modules, ensuring a clean system look. In addition, the NEMA 4X rating ensures the box is built for severe outdoor conditions. MC4 connectors, spring-loaded terminals and generous wiring space make the wiring a breeze. The Rapid Shutdown Box also acts as a combiner box, removing the need for additional hardware. Booth 3943.

Lightweight, flexible power conversion

Ideal Power

Ideal Power invented a new kind of power conversion architecture that delivers on flexibility, allowing you to enable or disable any features depending on project needs. At SPI, check out its 30-kW Stabiliti Series power converters. These multiport, compact converters are smaller, lighter and dramatically reduce installation costs while increasing return on investment. Ideal Power recently partnered with NEXTracker to implement it in various PV sites throughout North America. Booth 1433.

A top rail clip to rule them all

Heyco solar rail clips

Heyco has been busy this summer, introducing several new clips and wire management accessories for the solar market. Newest to the lineup are the SunRunner 4-2 and SunRunner 4-2U, which are top rail clips for various racking manufacturers such as Unirac, Ironridge, Everest, SnapNRack, Solar Mount and other similar racking profiles. The SunRunner 4-2 and SunRunner 4-2U are suitable for the new Enphase Q Cable. At the booth, you can also enter for a chance to win a Google Home. Booth 4762.

Drive down carport costs

Baja Carports InterSolar 2017 Booth Models

Baja Construction always has a standout booth, and this year its in-house construction team will be installing its signature Baja Solar Support System design, the “Braced Single Post Support,” built with high-tensile light gauge steel to support 24 solar modules (7.8 kW). Included in the structure is an EV Station for the hot red Tesla parked underneath. Meet Baja’s in-house designers, engineers and project managers and also make certain to visit Baja’s sponsored lobby lounge for food and beverages. I’m sure you’re already there. Booth 4155.

Improve your grip strength

Ace Clamp solar mount
AceClamps are factory-assembled clamps with patented design features that allow strong connections to standing-seam roof panels without the use of set screws or any other loose parts that could damage the surface of the roof panel. AceClamp designs have been vibration tested during the development stage and incorporate special locking features to ensure that the bolts do not back out when subjected to vibratory loads from wind flutter and light seismic activity. Booth 809.

OMG Roofing solar mount

OMG Roofing Products has introduced PowerGrip Universal for mounting solar racking systems on commercial roofs. PowerGrip Universal is designed to reduce or eliminate ballast in solar racking systems, so there’s less weight, material handling and labor on the roof. Made of heavy-duty cast aluminum, PowerGrip Universal offers 3,300 lbf of tensile strength, 2,500 lbf of shear strength and 2,000 lbf of compressive strength. It’s one of the strongest anchors on the market. Booth 629.

Solar Connections

The Standing Seam Power Clamp from Solar Connections can attach to virtually any standing seam profile and draws its strength from patent-pending WaveLock Technology with optional two, three and five points of attachment. The top can be custom drilled and tapped to fit any bolt configuration. Offering ease of installation, the Silver Bullet set screws include a rounded bullet tip to maximize strength while also keeping the paint finish and seam free from harm. Additionally, the Standing Seam Power Clamp is available in standard mill finish aluminum material, making it an item you can easily keep in stock when the need arises. Booth 1569.

Reinventing the ground mount

Nuance Energy

Nuance Energy’s patent-pending Osprey PowerPlatform could revolutionize ground-mounted solar projects. This earth anchor foundation system satisfies permitting requirements for virtually any site and soil type without the need for geotechnical reports or special inspections. It eliminates the need for heavy equipment or cement by enabling small, unskilled crews to install the entire platform quickly and easily using only handheld tools. Booth 2108.

Meet the 4G platform

Ginlong Solis inverter

Ginlong Technologies is now shipping its Solis 4G Platform. What you can see at SPI this year in booth 2427 is the Solis-1P(2.5-10K)-4G-US single phase string inverters, with high switching frequency; 2, 3 and 4 MPPTs designs; 97.8 percent peak efficiency (97.5 percent CEC); fan-less NEMA 4X / IP65 design, integrated AFCI; web-based and smartphone app monitoring, all under 44 lbs. The Solis 25K-66K-US three phase inverters are designed for all commercial and utility-scale installations with four MPPT designs and ultra-low start up volume that maximizes energy harvest. Booth 2427.

Five trackers to, um, track

SunLink TTD

SunLink’s TechTrack enables efficient load redistribution and allows the system to handle extreme wind with less steel, fewer foundations and lower cost. Now, TechTrack’s intelligent control system also delivers equally responsive control modes for snow, flood and O&M. The result is system level benefits, visible in SunLink’s Vertex data monitoring system. Rigorous testing to UL3703 further reduces permitting risk. Booth 3319.

Soltec

SF7 is the next-generation horizontal single-axis solar PV tracker from Soltec. Soltec says the SF7 enables up to 5 percent greater MW per acre than other trackers and does that with 54 percent fewer piles-per-MW, 15 percent less parts count and 58 percent fewer screw type connections than leading competitors. SF7 standard features include short tracker site-filling options, unique steep-slope tolerance of 17 percent NS, efficient self-powering and innovative cable management solutions for combining, fusing and protecting PV source circuits more economically. Booth 3640.

Solar FlexRack TDP 2 Turnkey Solar Tracker_2017

Solar FlexRack is launching its TDP Tracker with a new BalanceTrac design to increase energy yield and reduce balance of system costs. This TDP 2.0 Solar Tracker with BalanceTrac, optimized for 1,000- and 1,500-V modules, has greater rotational range of up to 120° and enables more modules per row (up to 90). The robust design delivers autonomous tables that increase site flexibility to maximize land use. Booth 2538.

AllEarth Renewable

AllEarth Renewables is showing off its new Gen 4 tracker which will be self-powered, to guard against the grid going down and will have expanded communication options, such as Wi-Fi, cellular and SD card enabled. It will come as a complete, pre-engineered system for easy, efficient shipping. Booth 626.

Array Technologies

Array Technologies is revealing the results of a recent TÜV Rheinland-backed independent report focused on solar tracker reliability. Array’s latest single-axis tracker, the DuraTrack HZ v3, is often touted for its reliability and lower cost of ownership. Array says DuraTrack HZ v3 is proven to be 300x less likely to experience catastrophic failure during wind events than more stow-reliant, single-row competitors. Booth 2919.

Page two has new on big-time collaborations, products for boosting performance, installing on shingles and more.

— Solar Builder magazine

Intersolar North America Showcase: Here’s what to see at this year’s trade show

APsystems: True three-phrase microinverters

APsystems YC1000

APsystems boasts an industry best-selling 3-phase solar microinverter and the industry’s first true 3-phase (phase-balanced & phase-monitored) unit, the YC1000-3. This model handles 208V or 277Y/480V grid voltages with 900 watts maximum output, 95 percent peak efficiency and comes with ZigBee communication and integrated ground. At 480V up to 11 units (44 modules total, 60- or 72-cell) can be linked in a single 15A circuit, and up to 14 solar modules (7x YC500s) in a string with a 20A breaker. Designed to operate from -40 F to 149 F degrees. Ten and 25-year warranties are available. Booth 9245.

Boviet Solar: Debuting two new solar modules

Boviet Solar

A new 290-W, 60-cell polycrystalline diamond-cut PERC solar module is one of the newest products from Boviet Solar’s full PERC production line completed in 2016. Also on display will be the new 300-W monocrystalline PERC Smart Module designed to harvest 25 percent more energy. In addition to free, 24-hour monitoring per module, the Smart Module also has module-level voltage shutdown to offer greater installer and firefighter safety. Booth 8317.

Ciel et Terre: Making floating PV happen in the U.S.

hydrelio floating solar

Ciel et Terre has completed large-scale floating PV systems in various market applications and countries, showcasing FPV as a real alternative to traditional PV in roof-top and ground-mounted systems. In the past year, the organization increased its U.S. reach with its first public utility project in Orlando, alongside its local Florida representative D3 Energy and in partnership with the Orlando Utilities Commission. Ciel et Terre installed a 31.5-kWp floating solar system on the OUC’s storm water storage reservoir, a dead water space at the facility, and is expected to generate up to 51,000 kWh per year. Booths 9744 and 9745.

Eaton: Control system to simplify microgrid deployment

Eaton microgrid system

Designed for critical applications requiring secure, efficient and reliable power, Eaton’s newest solution is engineered to deploy stand-alone power systems using existing and new assets with the adaptability to easily meet future needs. The system incorporates Eaton’s new Power Xpert energy optimizer controller and provides a modular, scalable approach to microgrid control, as well as accompanying services, such as microgrid feasibility studies, total system design, control system deployment, integration with existing third-party generation assets and critical loads, project implementation, commissioning and system start-up, and ongoing maintenance. Booth 8310.

EcoFasten Solar: New standing seam metal roofing application

EcoFasten

EcoFasten Solar has launched its newest product, SimpleBlock, a solution designed specifically for standing seam metal roofing applications. The versatile SimpleBlock provides a variety of options through compatibility with any rack manufacturer’s connection points (L-feet, posts), and will fit any double-lock standing seam. When used in conjunction with EcoFasten’s Mid-Clamp, SimpleBlock becomes a rail-free racking system featuring integrated bonding. The system meets and exceeds all known building codes and is UL 2703 listed, with product compliance determined through rigorous, uncompromised testing per UL 2703: First Edition. Due to such an overwhelming response to this innovative system, EcoFasten Solar is gearing up for high volume manufacturing to meet industry demand and will also be unveiling additional configurations for more seam options soon. Booth 9433.

Fronius: Offering its next generation solar solution

Fronius

Fronius introduces its next generation of solar systems to the industry, the Fronius Smart Solution. This satisfies all needs for residential and commercial systems: flexible system design, shade mitigation, NEC compliance, high performance and state-of-the art monitoring while keeping the number of components low and installation easy. The Fronius Smart Solution combines the benefits of traditional MLPE such as microinverters or DC optimizers with the ease of installation and cost-effectiveness of string inverters. The Fronius Smart Solution is the combination of cell-string optimized modules, the Fronius Rapid Shutdown Box, a Fronius SnapINverter, the optional Fronius Smart Meter and the Fronius Solar.web online monitoring portal. Check it out for yourself at the Fortune Energy booth. Booth 8519.

Heyco: A solution for every cable need

Heyco solar clips

Heyco’s new Edge Clips are ideal for use where holes cannot be used and adhesives are not acceptable due to temperature issues. If these won’t work, check out Heyco’s new SunRunner Vidrios, which are designed to mount directly onto the glass panel with compression force only — perfect for frameless PV modules. If neither of those pique your interest, check out Heyco’s SunBundler. Though not new to Heyco’s offering, the Heyco SunBundler has been receiving a lot of attention due to its 20 year warranty and unique design. Check them out at the CED Greentech booth. Booth 8311.

Ideal Power: The latest in power conversion innovation

Ideal Power

Ideal Power’s newest Stabiliti Series power conversion system is a grid-resilient 30-kW advanced power conversion system for system integrators and project developers who need to efficiently connect distributed energy resources to the grid. Stabiliti is the next generation of Ideal Power’s patented Power Packet Switching Architecture (PPSA) technology and incorporates numerous new features and benefits for commercial and industrial customers. The Stabiliti Series is available in two versions: dual port AC-DC bi-directional and multi-port AC-DC-DC bi-directional. Ideal Power’s John Merritt will be speaking on July 10 from 12-12.30 p.m. at the ‘‘Islands, Mini-Grids, Microgrids & Energy Storage’’ session. His talk will explain how solar-plus-storage systems can become microgrid-enabled with multi-port conversion technologies, creating energy resilience and reducing reliance on backup generators. Booth 8110.

JLM Energy: Patent-pending ‘microstorage’ technology

JLM Energy Phazr

Phazr, the first in JLM’s MicroStorage family of products, is mounted seamlessly behind the solar panel. Phazr is designed for large-scale, solar-plus-storage applications and is also perfectly suited for smaller residential and commercial installs. The simultaneous nature of electron flow is unique to JLM’s patent-pending technology. This is included in JLM’s energy technology bundle and is operated by Measurz software, which continually observes energy usage patterns and utilizes a variety of strategies to maintain a pre-set budget determined by the customer. Booth 8134.

Pika Energy: Partnership with Panasonic on solar smart battery

Pika_MAY17_006_web

Panasonic Eco Solutions North America and U.S.-based inverter manufacturer Pika Energy Inc. are partnering to offer a DC-coupled solar smart battery — Harbor 10P/15P — that will begin shipping in late 2017 and is available for pre-order today. The solar-ready Harbor Smart Battery combines Panasonic’s Lithium-Ion battery modules and Pika Energy’s power electronics in a slim, floor-standing, wall-mounted enclosure to provides 10 kWh or 15 kWh of usable energy and up to 6.7 kW of continuous power. Booth 8318.

Preformed Line Products: Speeding up rail-less mounting

Preformed Line Products

Maneuvering mounting rails can be the most demanding part of installing rooftop solar modules. But now installers can avoid that — and mount modules faster and easier — with the POWER DISK rail-less mounting system from Preformed Line Products. POWER DISK is a unique roof attachment that can go anywhere on residential rooftops. It does not need to be secured to rafters. Install solar modules in four simple steps: 1. Snap chalk lines. 2. Mount POWER DISK bases anywhere on the roof deck. 3. Set solar modules in place. 4. Spin the disks to vertically adjust height to roof undulations. Booth 9449.

Quick Mount: New series for comp/asphalt shingle roofs

Quick Mount

Quick Mount PV engineered its patented Elevated Water Seal Technology into an integrated L-foot and flashing for cost-effective, super-fast, single-bolt installation with unparalleled waterproofing. The L-Mount Series comes in single- and double-slot options for maximum versatility and works with all leading racks. L-Mounts are designed for simple lag-bolt installation onto existing composition/asphalt shingle roofs. The L-Mount features a 9-in. by 12-in. aluminum flashing with alignment notches and rounded corners to easily slide under shingles and speed installation. No shingle cutting required. Like all Quick Mount PV products, the L-Mount meets or exceeds roofing industry best practices and comes with a 25-year warranty. Available in mill or black finish. Booth 9411.

RBI Solar: Ground mount, ballasted, roof mount and canopy solutions

RBI solar Logo

RBI Solar is one of the top turn-key solar mounting solutions suppliers in the United States for ground mount, ballasted landfills, roof mounts and canopy/carport structures. As a single-source provider for commercial and utility-scale PV projects, all responsibility for the design, engineering, manufacturing and installation of the most efficient PV Racking systems in the marketplace is completed in-house by the RBI Solar Team. Committed to providing value from conception to completion, RBI Solar’s customers receive cost-effective and durable racking solutions for each project site to aide in reducing the overall project costs. Booth L9008.

SimpliPhi: Plug-and-play storage

SimpliPhi - AccESS - 300 DPI

Developed in partnership with installers, SimpliPhi Power’s AccESS has been installed in a variety of locations, including a commercial “glamping” resort, Flying Flags, and is positioned for hundreds of residential installations in partnership with Civic Solar’s SGIP projects. The AccESS provides power security that is safe, reliable, non-hazardous and efficient. The fully integrated solution includes the SimpliPhi award-winning battery technology, Schneider Electric inverter charge controller, associated power electronics and overall system management. Pre-programmed software settings and performance monitoring complete the solution. Booth 8124.

Smappee Plus: New advanced energy monitoring

Smappee Plus

Now entering the U.S. solar market, Smappee Plus is the latest innovation from Smappee’s burgeoning energy monitoring solutions which have seen widespread adoption across Europe since 2012. The product combines Smappee’s patented NILM (Non-Intrusive Load Monitoring) technology with submetering clamps to measure real-time energy use from appliances throughout a user’s home including those with variable output or similar energy consumption patterns, giving previously undetectable transparency to energy use. Head to the Impress Lounge across the street from the Moscone Center for more info.

Solar-Log: Enhanced PV monitoring portal allows for more installer services

solar log pv monitoring

Solar-Log’s new WEB Enerest is an enhanced PV monitoring portal that works in combination with Solar-Log’s data loggers to offer better monitoring and more efficient optimization of solar power usage. The new Solar-Log WEB Enerest portal is available in three different service levels and price classes to respond even more precisely to the differing needs of individual customer groups. The most advanced XL package allows installers and service providers to centrally monitor their entire fleet from one portal. This premium version provides near real-time visualization of plant error messages which can be quickly evaluated and managed. The portal allows the operator to remotely configure the Solar-Log®device, customize the portal design, and define plant owners’ access to the yield and plant information. Automated reports, integrated weather data comparison and the option to combine several plants with one account are just some of the comprehensive functions. Booth 9121.

SunModo: Debuting new solar awnings to shield windows, generate energy

sunmodo awning

The concept is simple: Replace traditional metal and fabric awnings with solar-power-generating panels that provide necessary protection from the elements while also replacing traditional electricity usage. That concept is coming to the marketplace as the SunShield awning system. It is being introduced by SunModo, a company that makes durable, easy-to-install professional racking systems. The SunShield awning system features a durable triangular aluminum frame as structural truss; and expands to a 35-degree tilt angle once installed. This compact triangle frame design easily accommodates both 60 and 72 cell solar panels. What’s more, SunShield opens the awning industry to 30 percent tax credits and provides a substantial new canvas for solar power generation. Booth 9539.

Tabuchi America: Expanded storage capacity

Tabuchi

Originally launched in the United States at Intersolar 2015, Tabuchi America is debuting the 2nd generation model of its Eco Intelligent Battery System (EIBS). Tabuchi’s all-in-one, easy-to-install system includes a 5.5-kW solar inverter and stackable 6-kWh lithium-ion batteries. The Tabuchi EIBS has the intelligence to maximize a homeowner’s savings in real time across different electricity tariffs. This DC-coupled system will meet advanced inverter requirements and will be 9540 compliant. Booth 8121.

Trojan Battery: AGM battery designed for solar installs

Trojan Battery

Trojan Battery Co. is launching a new line of maintenance-free, true deep-cycle absorbent glass mat (AGM) batteries specifically designed for solar and other renewable energy applications. The new Trojan Solar AGM line is manufactured in the U.S. Offering a three-year warranty for stationary applications, and tested to an eight-year design life under IEC 61427 standard for solar batteries, this initial release includes a wide range of Trojan Solar AGM models. With its non-spillable design, the new Trojan Solar AGM batteries enable installers to customize the use and position of the batteries in customer applications. Booth 8128.

— Solar Builder magazine

Wire management: What to look for when planning, purchasing your next solar system

Snake Tray's Cable Conveyance System

Snake Tray has developed a cable conveyance system that maintains a specific separation between cables that eliminates the need for upsizing cable gauges due to the derating cable because of bundling or piping.

Wires are good for two things: 1) Installing a kick-ass PV system 2) Tripping people up. To accomplish the first, you must avoid the second at all costs, which means implementing a sound wire management plan on projects of all sizes.

Planning

Just like the rest of the system, planning is important for both saving time and money. Tom Marsden and Vince Giglio from Heyco recommend laying out the cable routing on paper first before installing the solar cables. This will help you decide the best way to route the cables and what will be the most efficient use of cable mounting hardware.

Part of planning is of course purchasing, and knowing the most efficient ways to use what you’ve got.

“One way of saving time on installs would be to use stainless steel clips at the module level because you can install multiple clips in the same amount of time you can install a single zip tie, thus saving on labor costs,” says Vincent Marino, product manager for Nine Fasteners. “Also, when using micoinverters or optimizers connected to the panels, they can be applied prior to bringing the panel onto the roof.”

Nine Fasteners’ DCS-1307 Clip

Nine Fasteners’ DCS-1307 is its most popular clip. Constructed of stainless steel, it incorporates a rolled outer edge for maximum wire protection and is UL Certified. Its simplicity makes it cost competitive while still being manufactured in the United States.

Oh, and one trend to note while planning — pest management systems are starting to be required in rooftop installations, according to Marsden.

In a ground-mount, Roger Jette, president of Snake Tray, recommends keeping your power cables above ground when possible to remove the need to trench or thread cables through pipe.

“Besides being labor intensive, there is a potential of derating the current capacity of the cable,” Jette says. “With voltages now approaching 2,000 V, there is a high potential for problems if not enough attention is spent on the proper cable conveyance. Without a good cable conveyance plan, there is a potential for degradation of the cable insulation leading to arc failure.”

Let’s Get Wired: Five new wire management solutions to watch

We’ve heard plenty of horror stories from installers and manufacturers in regard to incorrect installation approaches or accidental errors, but the anecdotes that stand out most are those caused by wire management. Just seems silly to risk the performance of a $13,000 system by skimping out and choosing ties known to fail or clips known to dig into wires and cut them over time — the solar equivalent of losing a football game because of a missed extra point.

“Too many installers are sacrificing quality for costs. We have seen a number of installations

Heyco’s SunRunner Vidrio

Heyco’s latest clip, the SunRunner Vidrio, is intended for installation directly onto the solar module with compression force only. The SunRunner Vidrio is a stainless steel clip with a special TPE so it will not harm the glass surface and can accommodate glass panels from 0.13-in. to 0.25-in. thick.

where UV nylon cable ties are breaking, only to be replaced with more UV nylon cable ties,” Marsden says. “This scenario is no different than buying something for your home. Are you going to buy an appliance that needs to be replaced every two to three years or are you willing to spend a little more up front, knowing your product is backed by a warranty?” He points to stainless steel cable ties as a less risky solution.

Your other purchasing decisions dictate what wiring will need to be done as well, especially with those installing rail-less systems. The lack of a rail changes your wire management options.

“As a New Jersey installer, many jurisdictions require wiring inspections to verify that rails have been properly grounded,” says Chris Torre, installation manager at Green Sun Energy Systems, which has been using Quick Mount PV’s rail-free system, Quick Rack. “We’ve been able to eliminate the cost of the second truck roll to the site, saving an average of $300 to $400 per project. The system has integrated grounding pins located on the panel clamps, so the system can’t be grounded until the panels are installed. With this system, we’ve been able to install as many as 68 panels in a single day with a three-man crew.”

Chris Crowell is the managing editor of Solar Builder.

— Solar Builder magazine