How to install Iron Ridge solar panel racking
What you will need:
- Side walk chalk
- PVC pipe - Used to make story board sticks
- Tape measurer
- Chalk line
- Rubber mallet
Start by measuring out the set back distance on your roof. A set back is the space required by your local building code where you can not install solar panels. For example, your local code could require a 3’ space from the edge to the roof to the solar panels and 18” from the ridge to the panels. Mark out the set backs using sidewalk chalk. Yes, the stuff you get in the kids section at Walmart.
Then mark where your solar panels are going to go. To do this cut a section of PVC pipe the length of the solar panel and another one the width of the solar panel. Make marks on the PVC pipe where the mounting holes are located on the solar panels. There should be two mounting holes on the length of the solar panel and two on the width. Mark all these locations on the PVC pipes as this is where the rails for the racking will go.
Using the PVC sticks mark out all the corners of panels, this will allow you to see visually the layout of you solar system on your roof.
Once all the panels are marked on the roof you can mark where the rails will go. Find the mounting marks on the stick. Now make a mark on side of each of the rows where the mounting holes will go. Adjust that mark so it’s 3” up from the drip edge of the shingles (the bottom edge of the shingle). Snap a chalk line where the two rows of rails are going to go within the each row of panels.
Now look at your plans to determine where the flashing foots need to go along the rails. Once you have the relative location marked out where the flashing foots will go you need to locate where the rafters are so you can bolt the flashing to the rafters. Look for nail marks on the fascia. If you can see nails in the fascia, those nails are going into rafters. This is a good starting point if the nails are visible. If not you can use the rubber hammer trick. Pound the roof until you hear a solid sound. Mark this location on the rail chalk lines.
Mark the 3/8" drill bit that you will use for the pilot holes with a piece of tape at 4”. This is depth you will need to drill for the flashing bolts. Drill the pilot holes for the flashing. Mark the hole locations with chalk so you don’t lose them.
Now that you have the holes drilled you can start installing the flashing. Use a pry bar to lift up the shingles gently that are up from the pilot holes you drilled. Then insert the flashing under the shingles and tap it in place with a rubber mallet to see if there are any nails in the way. If there are we will go over that shortly. When inserting flashing, put a glob of sealant over the base plate of the flashing. Align the bottom of the flashing with the bottom of the shingle. If you run into a nail cut a little notch into the shingle. Now you can screw on flashing cap.
Now you’ll want to rough measure the rails. You want at least 1” on either side of the solar panels and about ½” in-between for the mounting bolts. Let’s cut and place the rails on the flashing. If you are using the BOSS splice from IronRidge, the BOSS can be inserted anywhere in the span. But if you are using the regular splice you will need to see IronRidge instructions to see where in the span you can place them.
Now you can bolt the rails to the flashing. Square, level and aligned. Start with the bottom rail and measure your set back distance and tighten the rail. Place a mark inward on each rail, we are doing 2’. Now measure diagonally. Adjust until both diagonal measurements are equal. Now use another rail to get all the rails on the same plane. Now torqued the bolts to 250 in lbs.
This completes the rail and racking install.