1. Layout
- Map out each array location and center on roof aesthetically
- Using crayons, mark out each corner of the array
- Snap straight lines horizontally to resemble rail location and placement
- Find your first rafter and ensure it lays no more than 18” from the edge of the array
- Mark your first rafter and then measure every 4’ or as dictated in plans to find each additional attachment location.
NOTE: you may have a column of attachment locations which are less than 4’ apart to ensure cantilevered overhang of solar modules does not exceed 18”).
2. The general installation method for attachments
Locate a rafter, drill a pilot hole and install the attachment.
NOTE: Use an assembly line technique with your team by having one person pilot drill rafters while the other lays out and stages attachments, and flashings and then follow up using an impact driver to lag in attachments. The objective is too keep progressing through each stage without delay. You must know what comes next and begin preparation for that task before the last task is finished.
- Ensure attachments are installed dead center of rafters
- Use an approved caulking, sealant or mastic for the roof type and a similar color to the roof you are working on. Caulking should be applied to the bottom of each flashing in a horshoe pattern as well as to the base of each attachment point or penetration location.
- The Flashings must be rated for the installation.
- Flat membrane boots and flashings must be installed by certified applicators of the membrane or material they are working on. OMG powergrip plus attachments, or pedestal attachments with membrane boots and stainless pipe clamp with membrane sealant are standard.
- For Standing Seam Metal Roofs the standard attachment method is an s5! Clip made for the standing seam profile. Ensure the correct one is ordered and being installed. During installation of clips, a ratchet NOT an impact driver should be used to torque attachments to roof.
- Composition shingles must use a Flashfoot2 or Flashvue by Ironridge or equivalently rated flashing. Each attachment flashing must adhere to the manufacturer’s specifications. Flashfoot2 and Flashvue must underlap 3 layers of shingles.
- Tile attachments must use a sub flashing and top flashing such as tile replacement flashings by Ironridge or a classic FHA with sub flashing. Typically Tile flashings have more flexibility to curve around the tile.
3. Installing Penetration Flashings for Attic Conduit
- Use an approved flashing for the roof type. Penetration flashings for conduit should be of FHA style (12”) with single flashing for composition shingle roofs and double flashings (sub flashings) for tile roofs. Metal and Membrane roofs will require a special flashing and should be installed by someone certified for the roof type and manufacturer to maintain warranty.
- It is recommended to use IronRidge Penetration flashings when penetrating attic runs for either composition shingle or Tile
- Use a proper Pipe Collar and seal Metal Pipe collars with M1 sealant. Use specified sealant for any other rubber collars and ensure sealant will not chemically degrade collar.
- Ensure Flashing slides up third course to be properly flashed or there is proper Cap sheet flashing for tile attachments along with sub flashings for Tile roofs
4. Installing Roof Top Conduit
- Rooftop conduit runs should be supported by straps and attached to the structural members of the roof by using an approved method. For Composition shingles Wicks uses the QM conduit mount. For Tile applications, Wicks uses the QM conduit mount for Tile. For Flat roofs we use Durablocks with reflective stickers and a slip sheet underneath each block.For metal roofs we use s5! Clips with conduit hanger straps attached to the female threaded hole.
5. Attaching Rail to Roof Attachments
Selection Standards: The Standard rail to be used is Ironridge Xr10 for flushmount systems and Xr100 or 1000 for systems mounted on flat roofs. All residential systems racking, attachments and clamps system MUST match the module frame color.
Methods for installation: Connect rails together either on the roof or if single story at the ground level. Having one person layout rails in front of attachments and stage the material
- Square bolts, T bolts, Grounding lugs, Splices and UFO attachments should be grouped separately and in an accessible pouch, container or bucket secured in a manner where they cannot spill.
- Begin inserting and attaching splices as needed per manufacturer specifications. Use specified type of screws and amounts
- Start on one end of the roof and attach the FIRST rail to the LOWEST mounting location of the first L foot.
- Without forcing rail allow it to sit levelly and as low to the roof plan as possible.
- Begin loosely attaching the rest of the rails
- Once rails are mounted ensure rails are fairly level by running a string or another rail across the tops.
- Once satisfied rails are fairly level tighten Square bolts sufficiently to the L foot.
6. Installing Microinverter or Module Level shutdown devices
- Install devices on center of module locations
- Connect devices together per plan
- Use approved wire support methods to manage wires and ensure no wires between device location touch roof plane
- Run Positive “Homeruns” for DC systems with RED PV wiring (USE2) from module to junction box
- Run Negative “Homeruns for DC systems with BLACK PV wiring from module to junction box
- Label all strings accordingly and legibly
- Make proper terminations in Junction box
- Pull all stickers off microinverters or optimizers and place legibly on a map with directional arrows. Take a picture of the completed map and upload into CompanyCam. Bring physical copy of map to the office and turn into the Project Manager
7. Install Rail Grounding Lugs
- Rail grounding lugs should be installed (1) one for every row of panels (every 2 rails) and installed in a reasonably straight line vertically from each row of panels and ran directly to the junction box without breaks in wire or splices. #6awg bare copper wire should be used at the array level.
8. Installing Grounding Wires
- Use an impact wrench with 7/16” socket, attache lugs to rail then #6awg bare copper from lug to lug in a straight line in closest and most efficient location to junction box
- Provide about 12”of excess bare wire at junction box location
- Using rated Strain Relief connector; run bare copper to inside of junction box, knocking out holes in box or drilling as needed
- Ensure any grounding straps that are required between rails or splices are installed as needed
9. Install MC4 connectors on Solar String homeruns inside Junction box for DC systems before laying modules!
10. Installing and Mounting Solar Modules to Frame
- Use an impact wrench with 7/16” socket, attache lugs to rail then #6awg bare copper from lug to lug in a straight line in closest and most efficient location to junction box
- Loosely lay down first module and connect wires
- Manage wires and secure to rail so that no wires are hanging once layed down (check this often as you install all the modules).
- Sight down array and panel as well as measure distance from rail to edge of module to ensure straightness
- Once confident in first panel being square, tighten UFO end clamps.
- Once confident in first panel being square, tighten UFO end clamps.
- Work in assembly line having one person grab the next panel from staged location while the other moves tools and secures wires of current panel
- Test string voltages as strings are completed
- Attach End Clamps. Wicks uses Ironridge CAMO end clamps as a standard method of install.
- Ensure all modules are level
- Be sure any visible module stickers from ground level are removed before breaking down the site
11. Pick up all trash, and ensure roof is free of debris
- Clean up all zip tie cuttings, plastic pieces, tape or any debris and trash off the roof
- DO NOT throw trash into customer bins
- Ensure gutters are not clogged with solar trash or debris
- Ensure trash bag is sealed and secured in truck to ensure no trash flys onto roadways