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HomeMy WebLinkAboutAPPROVED Solar Roof Installation Manual11551592-00-J SOLAR ROOF INSTALLATION MANUAL 21551592-00-J NOTICES The information in this manual is believed to be reliable, but does not constitute an express or implied warranty. Tesla reserves the right to make changes to its PV Modules and other products, their specifications, or this manual without prior notice. This manual applies to Solar Roof PV Modules, Roofing Tiles, Partial Tiles, the Prepared Roofing System elements which serve as their mounting system, and electrical wiring elements manufactured by Tesla. It is explicitly written for qualified professionals (“Installer” or “Installers”), including without limitation licensed electricians and NABCEP-Certified PV Installers. DISCLAIMER OF LIABILITY Tesla Incorporated (“Tesla”) and its subsidiaries are not liable for any damages caused by failure to follow the instructions and guidelines found in this manual, or from inappropriate use or maintenance of PV Modules. This includes, without limitation, any damages, losses, and expenses caused by non-observance of the instructions of this manual, as well as damages, losses, and expenses caused by, or in connection with, products of other manufacturers. solarsystemstechpubs@tesla.com CONTACT INFORMATION SOLAR SYSTEMS TECHNICAL PUBLICATIONS TESLA, INC 3500 Deer Creek Road Palo Alto, CA 94304 U.S.A. 31551592-00-J All instructions must be read and understood before attempting to install, wire, operate, or maintain a PV system. Failure to read and comply with any of the limitations noted herein can result in property damage, serious bodily injury, or death. The installer assumes the risk of all injury that might occur during installation, including, without limitation, the risk of electric shock. Tesla Solar Roof is engineered to safely withstand applicable live loads required by building code for steep slope applications. However, to ensure safety and maintain maximum roof life, walking on a Solar Roof should be avoided except by trained Tesla Solar Roof installation professionals and first responders. This is a common recommendation for other high-end roof types, including slate, clay, concrete, and composite tile products. IMPORTANT SAFETY INSTRUCTIONS NOTE TO TRAINED PROFESSIONALS DANGER: Tesla Solar Roof is slippery and is a fall hazard. Only access a Solar Roof with appropriate safety equipment and while wearing personal fall protection. An approved and safe walking platform should be used when accessing the roof to prevent falls, and damage to the roof. In addition, skylights, roof openings and light transfer panels must be covered with approved covering to prevent falls. In the event of a fire at the premises, rapid shutdown equipment in the array will reduce voltages and control the hazard for firefighter operations. Nevertheless the array wiring should be treated as potentially dangerous, especially if it is damaged by heat or flames. Inform the fire crew about the particular hazards from the PV system, and stay away from all elements of the PV system during and after a fire until the necessary steps have been taken to make the PV system safe. DANGER: SAVE THESE IMPORTANT SAFETY INSTRUCTIONS • Use qualified personnel for installation. Installing a Solar Roof requires specialized skills and knowledge. • Abide by local, regional, and national statutory regulations when installing the system, and obtain a building permit if necessary. • Use equipment, connectors, and wiring suitable for solar electric systems. • Work under dry conditions and use dry tools. • Use fall protection when working from heights of 6 feet (183 cm) or above. Follow Occupational Safety and Health Act (OSHA) or local governing safety regulations regarding Fall Protection. • Use insulated tools that are approved for working on electrical installations. • Wear suitable personal protection equipment (PPE) to prevent the risk of personal injury, such as fall hazards or electrical hazards. • Consult your local authority for guidelines and requirements for building or structural fire safety. 41551592-00-J SHEATHING REQUIREMENTS Tesla Solar Roof is installed over bare solid or closely fitted sheathing, as follows: • Exterior grade plywood: 15/32” nominal thickness or greater • OSB: 7/16” nominal thickness or greater • Solid sheathing boards: minimum of 1’x4’, closely fitted Do not install Tesla Solar Roof over widely spaced sheathing boards (sometimes referred to as “skip sheathing”). Retrofitting the existing structure with solid sheathing would be necessary. Verify the capacity of the existing structure to carry this additional load. As this procedure is beyond the scope of this manual, contact Tesla for engineering support prior to such modification. ROOF PITCH RANGE 2:12 - 20:12 ROOFING SPECIFICATIONS 51551592-00-J SINGLE COVERAGE UNDERLAYMENT FT COBALT FR is a self-adhering peel and stick roofing underlayment designed for sloped roof applications to help protect against water infiltration from ice dams and wind- driven rain. It is installed with Solar Roof V3 as a single layer application. PN:16113738-00-A ASTM D1970/ICC AC48 ICC AC188 ASTM E108 Class -A Full-Width roll: 38” with 3” Selvage Edge (Overlap Edge) Detail roll: 12-11/16” STORAGE For best results store Cobalt FR upright in its original packaging in a well ventilated area at room temperature 40˚F (4.4˚ C) and 90˚F (32˚C). If product has been stored at a high temperature above 90˚F (32˚C) it may become difficult to remove the release liner back- ing. To correct this, move product to cooler location. Once cooled, the release liner can be easily removed. COLD WEATHER APPLICATION Temperatures -4°F (-20°C) or below, a primer should be used and the upper most overlap edge blind nailed using 3/8” head roofing nails 1” or longer. Space nails at 12” intervals along upper side lap area 1” in from the edge using the guide marks. For best results, warm Cobalt FR to room temperature prior to application. STEEP SLOPE APPLICATION Steep slopes (5:12 or greater), high wind areas, or when installing at temperatures greater than 100°F (38°C), it is recommended to blind nail the selvage edge area as per above under cold weather application. ADDITIONAL NOTES FT Cobalt FR is a moisture and vapor barrier and therefore must be installed above a properly ventilated space(s). Follow ALL building codes applicable to your geographical region and structure type. Cobalt FR is not designed for indefinite outdoor exposure. Final roof- ing should be installed within 180 days of underlayment installation. DECK PREPARATION Cobalt FR should be installed over a clean, smooth, and dry deck. The deck should also not have any voids, protrusions, damaged or unsupported areas. For re-roofing projects, replace any water damaged sheathing and sweep roof deck thoroughly removing dust, dirt and loose nails. Do not install over old roof coverings. APPLICATION FT Cobalt FR maybe applied directly to plywood, OSB, fully cured concrete or masonry roof surfaces. Priming is not required for attaching Cobalt FR to dry wood, OSB or metal surfaces when the temperature is above -4˚F (-20˚C). Concrete and masonry decks should be primed with a solvent or a water based primer that meets ASTM D41 for self-adhesive membranes. Always work from the low point to the high point of the roof. 61551592-00-J FT Cobalt FR is to be laid out horizontally (parallel) to the eave with the printed side up. Apply underlayment over the Eave Flashing and offset the starter course 1/2” from the drip edge. Fasten each course at the up roof edge using nails every 12” on the guideline marks. At the eave drip edge, the underlayment will be fastened during the Starter Trim installation. On exposed overhangs, nail only on rafters unless the eave is soffited. Lap each succeeding course 3” over the preceding course, fully concealing the fasteners and the upside-down Tesla logo. Use a roller along the entire face of the underlayment to ensure an adequate seal. For end laps it is recommended to overlap a minimum of 6” and nail 1” in from the edges with 6” spacing between nails. End laps should be offset a minimum of 6’ on adjacent courses. Note: if underlayment will be left exposed for an extended period in high wind area it is also recommended to cap nail 1” in at 6” intervals along key exposed seams. This specifically includes along the outer edges of the roof along the rake or eave.RakeEave/Drip EdgeRafterRafterRafter Rafter12” 6” 72” Overhang Area No Nail Overhang Area No Nail Lap 6” min. Fasten every 6” with nails. CONCEALED NAIL METHOD End laps 3”1.50” 12”1” Top Corner of Underlayment 6” 1” 6” Horizontal laps Lap 3” min. Fasten every 12” with nails. 71551592-00-J SOLAR ROOF MODULE INFORMATION Dimensions 430 mm x 1140 mm Appx. 5 mm module thickness with 35.3 mm maximum height from deck Principal Materials Glass, Polymers, Fiberglass and Silicon Installed System Weight Textured Glass: 16.4 kg/m² or 3.4 psf Installed weights include all components of system above roof sheathing CERTIFICATIONS UL Listed ETL Listed UL 61730 UL 790 Class A UL 9703 TAS100 UL 1741 ASTM D3161 Class F Maximum open circuit voltage rating of connected branch circuits per diode (at STC): 13.34 V Maximum series fuse rating: 10 A Maximum system voltage: 1000 V (for installations above 2000 m but below 3000 m the system voltage is 877 V ) Temperature coefficient for voltage at open-circuit: -0.299 (%/°C) Temperature coefficient for maximum power: -0.395 (%/°C) Temperature coefficient for short-circuit current: 0.047 (%/°C) Protection Class: II Ambient temperature range: -40 °C to +40 °C Wire: 12 AWG, PV wire, 90 °C wet or dry Only PV connectors compatible with type PV-KST4/6II-UR or type PV-KST4-EVO2 (male), PV-KBT4/6II-UR or PV-KBT4-EVO2 (female) from Staubli may be used to connect to the PV module. ELECTRICAL CHARACTERISTICS These electrical characteristics are within ± 5% of the indicated values of Isc, Voc, and Pmax under standard test conditions (irradiance of 1000 W/m2, AM 1.5 spectrum, and a cell temperature of 25 °C or 77 °F). MODEL #SR60T1 14-CELL MODULE Irradiance (W/m2) Temp. (Celsius) Voc (V) Vmp (V) Isc (A) Imp (A) Pmax (W) 1000 25 13.34 10.99 5.65 5.32 58.47 81551592-00-J PVRSA Model: Solarglass Roof Rapid Shutdown Array Category QIJR, Report Date: 2020-05-01 TABLE OF ESSENTIAL ELEMENTS Function Manufacturer Model No.Firmware Versions and Checksums Certification Standard PVRSE Mid Circuit Interrupter (MCI)Delta Electronics GPI00010114 2 2.1.6 UL 1741 PVRSE Inverter Delta Electronics M4, M5, M6, M8, M10 Sys: 2.2.11 Pwr: 1.4.9 Safety: 1.4.3 UL 1741 PV Module Tesla SR60T1 N/A UL 61730 Diode Harness Tesla SRDTH N/A UL 9703 PV Wire Jumper(s)Tesla SR-BJ2X, SR-BJ3X, SR-BJ4X, SR-BJMini N/A UL 9703 Pass-Through Box Tesla SRPTB-4 N/A UL 1741 PVRSA Initiator 1 (See installation req. below)Non-Specific N/A N/A N/A 1 Dedicated PV system AC circuit breaker or AC disconnect switch, labeled per NEC 690.12 requirements. 2 Applies to variations of this part number, e.g. suffixes. Note: PVRSA installation requirements may reduce the effective equipment and component ratings below the individual equipment and component PVRSE ratings in order to achieve PVRSA shock hazard reduction requirements. PVRSA INSTALLATION REQUIREMENTS Max System Voltage 600 Vdc Max Array Internal Voltage After Actuation 165 Vdc (cold weather open circuit) Max Series-Connected Panels between MCI Output Connections:10 Max Series-Connected Panels Connected to MCI Inputs:5 OTHER INSTALLATION INSTRUCTIONS 1. MCIs shall be positioned at a slight angle during installation on roof deck to assist with water shedding. 2. An MCI must be connected to one end of each series string or mounting plane sub-array string. 3. Verification that MCIs are installed with 10 or fewer modules between MCI output connections shall be documented for inspection, by voltage measurement logs and/or as-built string layout diagrams. 4. The dedicated PV system AC circuit breaker or PV system AC disconnect switch shall serve as the PVRSA initiator and shall be sized and installed in accordance with NEC requirements. The specific part shall be identified on the as-built system drawings. Certification Mark of UL on the installation instructions is the only method provided by UL to identify products manufactured under its Certification and Follow-Up Service. The Certification Mark for these products includes the UL symbol, the words "CERTIFIED" and "SAFETY", the geographic identifier(s), and a file number. 91551592-00-J TRADITIONAL PV TESLA SOLAR ROOF DC modules DC modules Tempered glass Tempered glass Silicon cells Silicon cells Backsheet & encapsulant Backsheet & encapsulant Module J-boxes, PV wire and Listed connectors Module J-boxes, pv wire and Listed connectors Series strings below 600 V Series strings below 600 V DC - AC inverters DC - AC inverters Rapid shutdown (2014 or 2017)Rapid shutdown (2014 or 2017) SOLAR ROOF SYSTEM OVERVIEW A Solar Roof functions in fundamentally the same way as traditional roof-mounted PV systems. Sunlight is converted to DC electricity at each individual module. Individual modules are connected in series using diode harnesses to form a complete PV “string.” One or more strings connect in parallel at a typical string inverter to convert power to AC. PV Modules Full and Partial Roofing Tiles Flashings TILE TYPES 101551592-00-J ELECTRICAL SYSTEM COMPONENTS Evaluate preliminary PV layout prior to tear-off to verify that arrays will fit as designed. PV array layout must follow plan set when possible. Always communicate field changes with the installation hotline team. Field changes may cause BOM change (Diode Harness length and count, Jumper length and count, Partial Tile count). 1. Diode Harness (DH) 2. PV Module 3. Module lead with connector 4. Foot with Support 5. Footlap 1 2 3 4 5 111551592-00-J PASS THROUGH BOX Model #SRPTB-4 Listed to UL 1741 Provides a method of transferring up to 2 PV source circuits through the roof decking to inverters or additional PV arrays. MCI RAPID SHUTDOWN Model #EE-002605-003, Delta #GPI00010110 600V, 12A, NEMA 4X, MC4 Listed to UL 1741 PVRSE Center foot for PV module FOOT WITH SUPPORT Model #SR-FOOTSUP Listed to UL 790 Class A ASTM D3161 Class F TAS100 Edge foot for PV module FOOTLAP Model #SR-FOOTLAP Listed to UL 790 Class A ASTM D3161 Class F TAS100 PV MODULE Model #SR60T1 Listed to UL 61730 UL 790 Class A ASTM D3161 Class F TAS100 DIODE HARNESS Model #SRDTH Listed to UL 9703 JUMPER Model #SR-BJ2X, #SR-BJ3X #SR-BJ4X, and #SR-BJMini Listed to UL 9703 BRANCH SOCKET, STAUBLI Model #PV-AZB4 Listed to UL 6703 BRANCH PLUG, STAUBLI Model #PV-AZS4 Listed to UL 6703 121551592-00-J 1/2 PARTIAL TILE Model #SRNFT1/2 1/3 PARTIAL TILE Model #SRNFT1/3 1/6 PARTIAL TILE Model #SRNFT1/6 2/3 PARTIAL TILE Model #SRNFT2/3 5/6 PARTIAL TILE Model #SRNFT5/6 FULL TILE Model #SRNFT1 ROOFING TILES, FULL AND PARTIALS Listed to UL 61730 Listed to UL 790 Class A ASTM D3161 Class F TAS100 Center foot for Roofing Tile REDUCED FOOTLAP Model # SR-RFOOTLAP Alternate edge foot for Roofing Tile Roofing Tiles are non-electrical tiles buffering the solar array at all edge conditions. Roofing Tiles come in six different sizes to accommodate all areas of the mounting plane and are cross compatible with the PV Module hardware. The center foot is the Roofing Foot. The Reduced Footlap is used as an alternate edge foot. ROOFING TILES AND PARTIALS | STANDARD ROOFING FOOT Model #SR-FOOT 131551592-00-J A comparison of foot placement on starter course of High Wind installation versus standard installation is shown. The Full Tile, 2/3 Tile, and 1/3 Tile are speciality High Wind Tiles. The 5/6 tile, 1/2 Tile and 1/6 Tile use existing tiles with additional feet installed. STANDARD TILES 140-166 MPH WIND ROOFING TILES AND PARTIALS | HIGH WIND 1/6 TILE 2 FEET PN: 1525185-00-B 1 FOOT PN: 1525185-00-B 1/2 TILE 4 FEET PN: 1525183-00-B 2 FEET PN: 1525183-00-B 2/3 TILE 5 FEET PN: 1558939-00-A 2 FEET PN: 1525182-00-B 2 FEET1 FOOT 1/3 TILE PN: 1558938-00-APN: 1525184-00-B FULL TILE 5 FEET PN: 1558848-00-A 3 FEET PN: 1523807-00-D 5/6 TILE PN: 1525181-00-BPN: 1525181-00-B 3 FEET 6 FEET 141551592-00-J NAIL, RING SHANK ROOFING .120” x 1.25”, COLLATED, HDG SCREW, CONCRETE 0.25” X 2.25”, HEX WASHER STAINLESS STEEL SCREW, PHILLIP, MODIFIED TRUSS HEAD, SELF DRILLING #8-18 x .5”, STAINLESS STEEL SCREW, PHILLIP BUGLEHEAD, DK #8 X 1” COATED SCREW, SQUARE DRIVE CONCEALOR BONDED WASHER #10-13 x 2”, GALVANIZED RIVET, BLIND, DOMED 0.125” OD 0.125-0.187” MATERIAL THICKNESS SCREW, PHILLIP BUGLEHEAD #8 X 3” COATED WASHER, BONDED SEALING, 0.25”, STAINLESS STEEL FASTENERS Ridge and eave flashing systems are designed to ensure that embers cannot enter into the building in the event of a wildland fire. 706A.2 REQUIREMENTS. Ventilation openings for enclosed attics, enclosed eave soffit spaces, enclosed rafter spaces formed where ceilings are applied directly to the underside of roof rafters, and underfloor ventilation openings shall be fully covered with wire mesh, vents, other materials or other devices that meeting one of the following requirements : 2. Vents complying with all of the following: 2.1 The dimensions of the openings therein shall be a minimum of 1/16-inch (1.6 mm) and shall not exceed 1/8-inch (3.2 mm). 2.2 The materials used shall be noncombustible. 2.3 The materials used shall be corrosion resistant. VENTILATION AT THE EAVE AND RIDGE 151551592-00-J RIDGE VENTILATION FLASHING ASSEMBLY 1. Flashing, Ridge, Cap 2. Flashing, Cleat, Vented 3. Bracket, Ridge 4. Roofing Module 1 2 3 Ø 3 m m TYP. Solar Roof is vented using a ridge vent system. The ridge cap assembly consists of a Ridge Cap, Vented Cleat Flashing, and Ridge Bracket. The Vented Cleat has 3 millimeter round holes that are installed along the entire length of the ridge.7/8” (22.5 m m) 1/4” (7 m m) 1-3/8” (34 m m) 10’ 2 4 VENTED CLEAT FLASHING PN: 1505364-01-A 161551592-00-J 3 m m x 12 m m SLOT EAVE VENTILATION FLASHING ASSEMBLY 1. Flashing, Eave 2. Trim, Starter 3. Roofing Module Solar Roof is vented at the eave using the Starter Trim. The Starter Trim has 3 millimeter x 12 millimeter square slots and is installed along the entire length of the eave.1-1/4” (30 m m) 3-1/8” (79 m m) 10’ STARTER TRIM PN: 1508606-01-A 1 2 3 171551592-00-J STEPPED HIP DETAILSTEPPED RIDGE DETAIL OBSTRUCTION DETAIL VALLEY DETAIL FLASHING COMPONENTS 181551592-00-J TRIM, VALLEY FLASHING, HIP CAP 3 15/16" 2 5/16" 10' FLASHING, EAVE 2 1/8" 2 5/16" 10' FLASHING, RAKE 10' 1 3/4" 1 5/16" 3/4" DECK, C CHANNEL 15 11/16" 9 5/32”- 9 11/16" 1 3/4" TRIM, RAKE FLASHING, SIDEWALL STEP 3 5/32" 1 3/16" 10' TRIM, STARTER 10' 11" 11" FLASHING, VALLEY 7 1/2" 22 3 / 1 6 "25 11/16"16 5/32"18 1/2" 4 5/16” 4 ²5/32" 9 ²7/32" 28 11/32" 3 7/8" 26 11/32" 9 1/16" FLASHING, CAP, RIDGE 191551592-00-J RIDGE FLASHING VENTED RIDGE FLASHING 2 Self Tapping Screws per Vented rail. RIDGE END CAP TRIM 4 Self Tapping Screws per End Cap. RIDGE CAP FLASHING 4 Self Tapping Screws per Ridge Cap. X4 X2 X4 RIDGE BRACKET 4 Self Tapping Screws, 2 per side. X4 201551592-00-J VENTED RIDGE FLASHING PEAKWALL SUPPORT RAIL 2 Self Tapping Screws per Vented rail. 2 Self Tapping Screws per Support rail. Peakwall end cap trim 3 Self Tapping Screws per End Cap. PEAKWALL CAP FLASHING 3 Self Tapping Screws per Peadkwall Cap. X3 X2 X3 PEAKWALL BRACKET FLASHING 4 Fasteners per Peakwall Bracket Flashing.Installed every set of feet appx. 15" intervals in High Wind Areas. PEAKWALL FLASHING X4 211551592-00-J SUPPORT BRACKET Fasten Support Bracket under Trim if it fits. In areas where the Support Bracket does not fit, no Brackets need to be installed. Fasten the Support Bracket to the deck using a minimum of 4 screws. HIP FLASHING STARTER HIP CAP HIP CAP 2 Self-Tapping screws per side to C-Channel. X4 X2 HIP TRIM 2 Self-Tappers through the C-Channel. 1 Self-Tapping screw through Support Bracket (if installed). X3 221551592-00-J VALLEY FLASHING SUPPORT BRACKET Install a minimum of 1 Support Bracket per Trim and every 7". Minimum of 2 Fasteners per Support Bracket. X2 VALLEY TRIM 2 Self Tapping Screws fastened to C-Channel. 1 Self Tapping Screws fastened to Support Bracket. 1 Self Tapping Screw to lock Trim angle. X3 231551592-00-J 4 3 2 1 14" Pipe Flashing with Top Extension riveted to C-Channel. 5 5 5 HEAT VENT FLASHING Install Obstruction C-Channel (1) every 6". Trim and fasten the Lower Extension Flashing (2) to the rails 1" back from edge using rivets. Lap the tile level Pipe Flashing over the Extension Flashing, and fasten with rivets uproof (3). Fasten with rivets downroof through both flashings (4). For larger Pipe Flashings, lap and rivet an Upper Extension Flashing (5) uproof. Rivet extension to the Obstructions C-Channel 6" OC, 1" back from edge. Rivet through both flashings downroof and uproof 6" OC, 1" back from edge. 241551592-00-J PV MODULES AND WIRING CANNOT INTERACT WITH METAL FLASHINGS Once energized, all components of the Solar Roof photovoltaic DC circuit, including the Diode Trunk Harness, all conductors, and the Pass Through Box must remain in isolation from metal flashings. The PV array must be buffered by non-energy generating Roofing tiles, which are designated in the project plan set. Never locate PV Modules at true edge conditions, such as in first row at the eave or in the top two rows at the ridge. Never locate PV Modules on the mounting plane where they may contact transition, headwall, obstruction or valley flashings. A PV Module may experience conditions that produce more current and/or voltage than reported at standard test conditions. Follow the requirements of the National Electrical Code (NEC) in Article 690 to address these increased outputs. In installations not under the requirements of the NEC, multiply the values of Isc and Voc marked on the Solar Roof PV Modules by a factor of 1.25 when determining component voltage ratings, conductor ampacities, overcurrent device ratings, and size of controls connected to the PV output. ELECTRICAL SAFETY PRECAUTIONS 251551592-00-J • Do not handle PV Modules under wet conditions unless wearing appropriate protective equipment. • Do not attempt to make an electrical connection with wet, soiled, or otherwise faulty connectors. • Do not wear metallic rings, watchbands, earrings, nose rings, lip rings, or other metallic objects while installing or troubleshooting PV systems. • Do not use a PV Module with broken glass. A damaged PV Module cannot be repaired and must not be used. • Do not open electrical connections or unplug connectors while the circuit is under load. • Do not use PV Modules near equipment or in places where flammable liquid, gases, or other hazardous materials are located. • Do not apply paint or adhesive to any module top surface or backsheet. • Do not drop PV Modules or allow objects to fall on modules. Do not leave a module unsupported or unsecured. • Do not disassemble or modify PV Modules in any way. Doing so may degrade performance or cause irreparable damage and will void any applicable warranties. • Do not direct artificially concentrated sunlight onto the PV Module. • Do not allow children or unauthorized persons near the installation site or storage site of modules. • Wear non-slip gloves when carrying PV Modules. Exercise caution when transporting and installing PV Modules. • Do not lift any module by the module’s junction box or electrical leads. MATERIAL HANDLING 261551592-00-J STARTER COURSE | FULL TILE The start of the array is indicated in the project planset. If the first tile is a full tile, use the Starter Course Jig in the orientation shown above to position the first row of feet. Ensure that the inside edge of the Starter Trim is free of any debris that would push up the jig from its correct position. 1. Abut the jig to the inside corner of the Starter Trim. 2. Align with the top edge of the Deck C-Channel to give the tile a 1” spacing the rake edge. 3. Fasten first row feet. Continue along the eave by snapping a second jig into the first jig. 4. Install the first tile by engaging the Uplift Clip into Foot slot then fastening the remaining feet. 271551592-00-J The start of the array is indicated in the project planset. If the first tile is a partial tile, use the Starter Course Jig in the orientation shown above to position the first row of feet. 1. Align the feet to the edge of the Starter Trim using the notches in the foot. 2. Align with the top edge of the Deck C Channel to give the tile a 1” spacing the rake edge. 3. Fasten first row feet. Continue along the eave by snapping a second jig into the first jig. 4. Install the first tile by engaging the Uplift Clip into Foot slot then fastening the remaining feet. STARTER COURSE | PARTIAL TILE 281551592-00-J STARTER COURSE FOR 140 TO 166 MPH WINDS In high wind regions, additional feet are installed at the first row starter course to prevent tile uplift at the eave. Example of Jig use with partial tile. STANDARD INSTALLATION A standard full tile starter course installation has three downroof feet. Dimensions from 1st Foot on Left (IN) Tile Size 1 2 3 4 5 6 1/6 5 ¾"9 5/16" 1/3 7 1/2"15 1/16" 1/2 5 3/4"11 1/4"18 13/16"24 3/8" 2/3 7 1/2"11 1/4"18 13/16"26 5/16"30 1/16" 5/6 5 3/4"11 1/4"18 13/16"26 5/16"33 13/16"39 3/8" FULL HIGH WIND INSTALLATION A high wind full tile starter course installatio has five downroof feet. 1/3 TILE 7 1/2" 15 1/16" 291551592-00-J STEP 1 IDENTIFY PARTIAL TILE SYMBOL Identify partial tile size. Each partial tile is indicated by a unique symbol on the High Wind Jig. STEP 2 ENGAGE JIG ONTO FULL TILE Locate the notch with the partial tile symbol at the left-most position that ALSO has the full tile symbol. Position this notch over previously installed full tile right-most foot (1). Install feet ifor partial tile in notches with symbol (2). FULL TILE PARTIAL TILE 1 2 STARTER COURSE FOR 140 TO 166 MPH WINDS 301551592-00-J Continue the Roofing Tile and Partial Tile uproof row by row. 1. Position the row spacing (tile reveal) using the timing marks on the Footlap. 2. Adjacent Roofing Tiles will share a Footlap. ARRAY LAYOUT & SECOND ROW 3. Engage the Uplift Clip(s) to a minimum of one foot downroof. Each tile needs to be anchored with at least three feet total. 4. Install the appropriate tile level flashings over the Roofing and Partial tiles at edge conditions. 311551592-00-J OUT IN The Mid-Circuit Interrupter is installed directly above the row or sub-string of modules that connects to its input. Abide by all MCI Manufacturer instructions when installing the MCI. Fasten the MCI to the deck using standard fasteners. The input leads are shorter and connect to the positive and negative terminations of that Diode Harness sub-string. The output leads connect to the Diode Harness sub- strings above and below. MID-CIRCUIT INTERRUPTER • Position the MCI at a slight angle to assist with water shedding. • Install the MCI between the module feet. The MCI cannot interfere with module supports. • Do not install the MCI in a manner which would cause it to raise the PV Module above it. For example, directly underneath a Footlap. • Provide enough clearance so the MCI does not directly contact the downroof module. The MCI cannot come in contact with the glass or backside of a module. • For ease of installation, position the MCI to the right or left of the last PV Module. IN OUT OUT MCI LOCATION POWER FLOW DIAGRAM INSTA LLATION BEST PRACTICES 321551592-00-J A serpentine wiring schematic weaves back and forth along the PV array. Connect the 5x Input Harness to the MCI input, then connect 10 or fewer Solar Roof PV Modules between MCI units. • Do not swap input and output leads, this may overpower the MCI. • Maximize the number of tiles per MCI (both input and output). To minimize hardware costs, avoid connecting MCI output directly to output of another MCI where feasible. • An MCI must be connected to one end of a series string or sub-array string. It is not required on both ends. Whether the MCI is connected to the “first” or “last” module in a series string is not important. • Use the wire management features on the module feet to hold up to 3 conductors. Tuck the Diode under the module. • For areas with skipped PV Modules, such as at obstructions, install a Mini Jumper at the diode to close the circuit. Failing to do so will result in an open circuit and the entire string will not yield any energy. SERPENTINE WIRING SCHEMATIC Output JumperModified Cable Lengths on 1, 2, 3, 4 and 5x 5x Input Harness 5x Input Harness with Output Jumper tucked into wire management feature. MCI MCI MCI + - I-1 I-2 I-3I-4 I-5O-1O-2O-3O-4O-5O-6 O-3O-2O-1I-4 I-31-2I-1O-9O-8O-7 O-4O-5O-6O-7O-8O-9O-10 O-5I-5I-4I-3I-2I-1 O-4O-3O-2O-1 O-6 Example PV Array with 3 MCI Units 331551592-00-J Connect 3 to 5 Solar Roof PV Modules to the MCI input (80V max). These modules will power the MCI. The wiring bundle contains the positive and negative input leads and a jumper to connect to the next (output) diode harness. MCI INPUT ASSEMBLY Input Diode Harness Output Jumper MCI #1 MCI Wiring Bundle PV Modules If not pre-assembled,connect the positive (female) and negative (male) input leads into the MCI. Connect the negative (female) output lead to the MCI. Plug the PV Module into the Diode and tuck the Diode under the PV Module. The input wire will wrap back to the MCI while the output wire extends to the next (output) 10x diode harness. SERPENTINE WIRING SCHEMATIC 341551592-00-J Connect 10 or fewer Solar Roof PV Modules between MCIs. MCI OUTPUT ASSEMBLY If not pre-assembled, connect the positive (female) and negative (male) input leads into the MCI. Connect the negative (female) output lead to the MCI. The output wire will wrap up to the next row. The module leads on the subsequent row will be reversed to connect to the Diode. MCI #2 Connection to Output Jumper 5x Diode 5x Diode SERPENTINE WIRING SCHEMATIC 351551592-00-J STRING TESTING PROCEDURE Solar Roof installation requires course by course testing and verification, of all strings, to ensure that all modules are connected properly and also that all modules are producing as designed. This testing is critical as any diagnostics and/or remediation of underperforming or miss-installed systems is challenging and time consuming. • The data tested/collected is the Open Circuit Voltage (Voc) of the PV Modules when installed in series. • When installed in series the Voc of these modules measure in a cumulative function. • This number is representative of the nominal Voltage of the modules (13.34) multiplied by the number of modules. • During the course of the installation ambient conditions may change depending on temperature and cloud cover being the biggest factors. Take a test reading from one PV module at beginning of population, after a break, or any big change in sunlight. End of job verification requires submittal of the string level testing to the BOLT platform (JCO) to ensure this information is available through the lifetime of the system. Additionally, notations confirming that stringing as designed matches the string as installed are a requirements. 1. Voc is checked by plugging in to both ends of the circuit. Note: This may be challenging due to split arrays. Test each 10 x and MCI 5 x rows as you go. Typically, this happens at each completed diode section from the homerun or bypass section. 2. Verify that the Voc has jumped by the correct amount (# Modules x ~Voc). Voc should increase to the relative control value multiplied by the number of modules in the row. 3. Record values on Voc sheet for each string. Writing down the size of the row helps find inconsistencies or issues that might arise with the diodes or wiring. 4. Always get a picture of the final Voc for the string. This information is required as part of the job close out portion. 361551592-00-J VOC TESTING CURRENT PROCESS – MCI BYPASS UNIT Mid-Circuit Interrupters effectively block the flow of energy when in shut-off mode preventing the capture of string level Voc. The MCI Bypass Unit solves this issue by sending enough power to the MCIs to activate them, allowing current to flow normally. As the array is installed ensure that the low end jumper remains exposed and travels up the mounting plane along with the installation, this jumper will be used as one end of the circuit and will need to plug in to the MCI Bypass Unit. Complete the circuit by connecting to the modules below and the bypass unit. As long as the unit power source is charged the string will now be powered. Utilize a multi-meter to determine output and record on the Voc Checklist. Also, ensure that the diodes have either a PV module or bypass jumper in them before testing a completed row. CURRENT PROCESS – NO MCI BYPASS UNIT If no Bypass Unit is available the course by course testing is conducted just after the diodes are plugged into the modules, but BEFORE they are connected to the rest of the string. Utilize a multi- meter to determine output and record on the Voc Checklist. Extra care needs to be taken to ensure that connections made to the surrounding Diode Trunks are correct. This method generates a Voc count ONLY for the tiles in that subsection. This could read across mutiples courses of PV tiles. MCI BYPASS UNIT MULTI METER MCI MCI JUMPER 371551592-00-J BRANCH SOCKET AND PLUG Verify transition location on plan set. Install Pass Through Box using wiring methods and materials that comply with Article 690 and Chapter 3 of the NEC and local regulations. PASS THROUGH BOX Branch Sockets and Branch Plugs are used to make parallel connections between PV strings before entering a Pass Through Box. These connectors are installed on the roofing surface under the modules. ARRAY 1 ARRAY 2 + - + - BRANCH PLUG PASS THROUGH BOX BRANCH SOCKET 381551592-00-J MAINTENANCE Disengage Uplift Clips in the tile by gently prying the tile up using a door lifter (tile removal tool). Push the tile uproof to disengage the uproof hooks from the feet, then slide the tile downroof and out of the array.