One of the most important aspects of any solar PV installation on a metal roof is wire management, but even seasoned professionals can find this task confusing. From ensuring proper conductor positioning during module installation to keeping wires clear of the roof and seamlessly connecting your array of modules to the inverter, the process demands attention to detail.
When it comes to best practices for wire management, it’s important to:
- Prepare your panels
- Plan your layout
- Pick the right method
Exploring Solar PV Mounting Options on Metal Roofs
There are two main ways of attaching solar PV modules to your metal roof:
- Rail-based module mounting is a common installation method where roof mounting attachments support rails that secure the solar modules in place.
- Rail-less (direct-attach™) module mounting uses the seams of the standing seam metal roof or the exposed-fastened roof’s trapezoidal or corrugated ribs as the rails.
Installation comparison: Rail-based PV mounting on the left and rail-less PV mounting on the right.
Meticulous planning before you get onto the roof is key. While these concepts are good practice for either type of solar mounting method, wire management best practices are more critical for rail-less installations.
Module Preparation Matters!
Prioritizing module preparation on the ground minimizes time on the roof, which equates to less time on the job. The cable conductor leads on the underside of the modules are long and can get lost beneath the modules during installation. Flipping large modules over or trying to reach beneath them to find conductor ends while on the roof can be difficult, time-consuming and stressful. Coiling up excess wiring and positioning conductor ends beforehand not only keeps wires off the roof, but also streamlines connections during installation.
Prepping modules on the ground saves time and hassle.
Crafting a Wire Management Plan
Resist the urge to rush onto the roof with equipment in hand. Instead, invest time in meticulously planning your wire management strategy on the ground. From optimizing string designs to minimizing cable lengths, wire management planning proves instrumental in saving time and labor.
The Right Accessories for Your Solar Array!
The S-5! MLPE Mount™ secures and bonds microinverters and power optimizers to solar PV panel frames, providing the versatility needed to better manage module-to-module wire management. Plus, the MLPE Mount electrically bonds the equipment together to easily comply with grounding requirements.
The S-5! MLPE Mount simplifies module-to-module wire management.
String Design Strategies
Deliberate string design plays a pivotal role in optimizing wire management. By strategically positioning string ends and minimizing jumper lengths, you pave the way for a hassle-free installation process. Whether adopting the direct method or the trunk method, tailored string designs ensure an organized and efficient layout.
Choosing the Right Wire Management Method
One common option is the direct method, in which you attach jumpers at the end of each string and then run them the length of the panels to the homerun.
Direct Method Snapshot:
- Wires run “directly” to the homerun
- Can be laid out ahead of module installation
- Can be laid out on-the-fly
- More labor-intensive
- Less cost-effective
- Becomes more difficult as the scale of the array increases
Larger and more complex systems often benefit from the trunk method. A trunk is a wire management tray or conduit where jumper wires are bundled together and routed to the homerun.
Trunk Method Snapshot:
- More hands-on time and preplanning module installation to determine where cables go
- Wiring is physically laid out before modules are installed
- Use of cable trays (preferred method) or conduit
- Simplifies wire routing
- Less installation time
To see these methods in action, watch the video demonstrations on our blog!
Plan your next residential or commercial solar project by visiting our online solar calculator.
Ideas to Hold Onto
By adhering to best practices for wire management, such as module preparation and strategic string design, you can save time, money and hassle on your next solar PV installation. Looking for The Right Way™ to attach solar PV to your metal roof? Visit www.s-5.com for more information.
About S-5!
Founded by a veteran metal roof expert, S-5! has been the leading authority on metal roof attachment solutions since 1992. S-5!’s zero-penetration clamps and lifetime brackets attach ancillary items to standing seam and exposed-fastened metal roofs respectively, while maintaining roof integrity and warranties. Made in the U.S.A., S-5! solutions are engineered for a variety of roof-mounted applications and are now installed on more than 2.5 million metal roofs worldwide, providing strength and longevity never before seen. For more information, visit www.s-5.com.
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