A Real Contender of an Installation with Rocky H.
This month’s install is a real contender, with a difficult project that took three hard, 12-hour-long days of work to complete, proving that with a little patience, anyone can be a champion. Rocky H., the champion in question, rose to the challenge and ended up with an exceptional solar array for his home! An “extreme DIY’er,” Rocky H. had no professional construction background but built his own house, garage, and workshop by himself.
“There was a large learning curve as I didn’t know anything about solar or DC wiring/properties, but it wasn’t anything that can’t be learned. You don’t have to be a licensed electrician to complete a solar system. Willingness to learn and research what you don’t know will get you there.” – Rocky H.
Rocky had the help of a little manpower from friends and family, as well as a 60ft. man-lift to help reach the rooftop a bit easier – with an 8/12 pitched roof, a ladder wouldn’t be quite as simple!
Interview with Rocky
How long was the full installation process from receiving your equipment to flipping the switch?
I ordered my equipment in May, but didn’t start installing until June. I had some things to install on my existing electrical systems before starting on the solar system. The actual installation took 3 twelve hour days. I installed the disconnect and inverter before starting on the roof. It took about 4 hours. The electrical inspection was two days later, and the system test with my utility company was two days after the electrical inspection. I will admit I had all my i’s dotted and my t’s crossed!
How many people did it take?
The first two days, it was just my father in law and I. We installed all the anchor points for the racking and then the racking itself. The second day we installed all the optimizers, optimizer cabling, grounded the racking system and starting running wiring to the inverter. The third day I had two more friends help. Finished up wiring to the inverter first thing in the morning and then installed all the panels. The 36 panels took us about 6 hours. It probably would have taken twice as long if we didn’t use a man-lift. I used a 60 ft. man-lift as I have an 8/12 pitched roof and the peak is about 40 ft high. I would recommend one if you can get one. It’s much easier than hauling everything on a ladder. Unless you have a big crew.
Did you have any previous construction experience?
I have never worked in construction, but I built my house, garage, and workshop. I’ve also helped my friends with their projects, etc. I’m 37 years old. I’m an extreme DIYer. I would say my working knowledge is probably better than most. There was a large learning curve as I didn’t know anything about solar or DC wiring/properties, but it wasn’t anything that couldn’t be learned. You don’t have to be a licensed electrician to complete a solar system. Willingness to learn and research what you don’t know will get you there. Will Burlin at Wholesale Solar was a big help. I probably came in thinking I knew more than I did, but he helped me bridge the gap on things I didn’t have experience with — like derating a panel to land a large enough breaker for my system. Trying to wrap my head around that one was interesting.
“Will Burlin at wholesale solar was a big help. I probably came in thinking I knew more than I did, but he helped me bridge the gap on things I didn’t have experience with like derating a panel to land a large enough breaker for my system. Trying to wrap my head around that one was interesting.” – Rocky H.
What was the most difficult part of the installation?
This may sound lame, but I stressed a ton about locating the center of my trusses. You can try to measure from the end of your roof, but that isn’t always accurate. I couldn’t find them using a stud finder, so I ended up doing it the old fashioned way and used a hammer and my ear just like finding a stud in the wall. It was pretty dang accurate. Within 3/8’’. Pounded a nail where the sound was more solid. If it was off, the flashing from the anchor would cover it easily. Overthought that part 100 times over. Also stressed about handling the DC wires coming from the optimizers. Was afraid of getting shocked, etc. After a little research, I found out that each panel in the string would carry approximately 1V until activated by the inverter. The system comes in many parts and seeing it sitting in my garage for a month before I attempted the install was intimidating. I just hoped it would all fall together once I began… and it did! The way they piece the system together makes it easier. I didn’t have to cut any of the rails. They come in lengths that seem to go together for any number of panel rows. All the paperwork they gave me had all the answers I would need. There were several attachments emailed to me that I had to read a couple of time before they were clear. https://youtu.be/hkT2fVZ9C5g
Were there any unforeseen additional parts or tools you needed?
There really weren’t any tools. Like I said before, I over-researched the process. I have most tools a general contractor would have, so I was ready. The one tool I’d recommend if you have a shingled roof is a Dasco shingle ripper pry bar. $20 on Amazon. It worked way better than a regular pry bar, saving me a ton of time. I found a guy using it for his panels via YouTube. You’ll have to supply the AC wiring and the breaker from the inverter to the disconnect and then to wherever you connect to the utility (meter socket, sub-panel). Any conduit needed. Metal conduit for DC/strings to inverter and metal or PVC conduit for AC wiring. I think labels now come with Wholesale Solar packages, I didn’t get any with mine (Our solar packages now come with a 55 piece pack of labels designed to meet 2017 NEC – Ed.) . I also had to supply some engraved plastic labels required from the electrical inspector and a couple from the local utility. pvlabels.com got them to me in 3 days and cheap!
How/Why did you choose to self-install?
My neighbor had a system installed by a contractor. I started asking him questions and we both thought we could install it ourselves and save a bunch of money. We were right! I have a 4,000 sq ft home and also a 2,000 sq ft home and was tired of high utility bills! Plus there are great rebates and tax savings. I’ll get 30-45% of my money back in tax credits and rebates.
“Rocky was on top of all the technical aspects of his project, he had clearly done his research and was asking all the right questions. Besides a little advice here and there, and a quick revision of the diagram, everything was smooth sailing” – Wil Burlin, Solar Technician
What was your primary reason for adding a DIY Solar Kit to your home?
To save money. After all my expenses it only came to $15,000. Another neighbor had a similar size system installed for over $26,000.(my system is a little larger too). I will be saving hundreds per month!
Anything else you’d like to add?
I will say I was a little skeptical to work with any solar company. I was afraid that after giving them money that I would be left in the wind if I ran into problems. Wholesale Solar really helped with everything. Everything from ordering to shipping was pretty easy. They provided all the engineering required for permitting and required by my local utility. I had a couple questions about grounding and some other minor things that were answered within a day if not the same day. At the end I needed my line diagram changed for my final inspection. My rep was on vacation, but another rep stepped in an handled it the same day. My rep came back the next day and made sure I had what I needed. There was a point were I got really frustrated with my rep because I couldn’t understand some of the technical aspect (derating I mentioned earlier) and my rep was very patient with me. I will be honest, I’m not the easiest person to deal with. My patience is really short when dealing with salespeople. But these guys aren’t pushy. They are really laid back. They don’t seem like they are pushing for a sale. They must really love solar! (We do! – Ed.) I’m now thinking about installing a system on my business office!
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