. .

RESIDENTIAL ARRAY DESIGN PROJECT

PHASE I FINAL REPORT

AIA . RESEARCH CORPORATION WASHINGTON, D.C.

AUGUST 25, 1981

Burt Hill Kosar Rittelmann Associates RESEARCH and SOLAR APPLICATIONS DfVLSION 400 Morgan Center Butler Pa. 16001

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RESIDENTIAL ARRAY DESIGN PROJECT

PHASE II FINAL REPORT

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AIA . RESEARCH CORPORATION WASHINGTON, D.C.

AUGUST 25, 1 ~81

Burt Hill Kosar Rittelmann Associates RESEARCH and SOLAR APPUCA TIONS DIVISION 400 Morgan Center Butler ,Pa. 16001

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INTERFACE CONTROL DRAWING INFORMATION

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INTERFACE CONTROL DRAWINGS (ICD)

BURT HILL KOSAR RITTELMANN ASSOCIATES

SCHEME NO. BHKRA-3

(1) Maximl.llD envelope dimensions and tolerances.

(2)

As the photovoltaic module was defined by AIA/RC the following is given:

Envelope dimensions

12 6 cm x 6 7 cm ( 4 9 • 6" x 2 6 • 3")

80 cm x 161.45 cm (31.56" x 63.56 11)

Cell to edge of glass

2.54 cm (1.00")

Tolerance requirement on envelope are met with standard glass

tolerance levels

Cell to glass edge tolerance is reconunended as + 0.318 cm (+1/8")

Location, configuration, and materials and finishes of output termina­

tions, with applicable user constraints (e.g., fastener torque and

polarity identification).

It was assumed for this analysis that Amp Solarmate® quick connectors were

installed on the back of each module. The Solarmate® quick connectors

(female) will be located 4.445 cm (1.75") from the long edge of the module

and 5.08 cm (2.00") from the side or short edge of the module.

The array wiring diagram, as attached, illustrates that 14-modules are

connected in series with 3-parallel connected circuits. Each of the cir­

cuits consisting of 14 seriesed modules yield 263.2 volts and 7.1 amps at

peak power. The peak array output is therefore 263.2 volts at 21.3 amps.

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(3) Mounting-hole or attachment provisions, materials and finishes of mounting

surfaces or frames, dimensions, and tolerances.

There is not a frame and therefore no mounting hardware attached to the

module. The proposed system is a "glue-on" adhesive system. The

following discussion will describe in detail the concept:

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DESCRIPTION OF ATTACHMENT AND SUPPORT FRAME CONCEPTS

ABSTRACT

The module attachment method and mounting frame is designed using a "glue on"

concept which relies on silicone adhesive/sealants to both structurally affix

the panels to a simple interfacing support frame and provide a long lasting

weathertight seal. This design approach represents a significant departure from

conventional mounting configurations which employ mechanical fasteners to

restrain the PV panels, as well as premolded rubber gaskets or gun-applied

sealants for water-tightness. By turning to an adhesive concept, the number of

mechanical fasteners can be reduced which can lead to a reduction in the number

of field installation steps. The research carried out thus far indicates that

no significant problems exist to spell failure for this concept. The support

frame is a premanufactured item of radical design and is conceived for absolute

simplicity in use of materials, fabrication, and installation.

SILICONE CONSTRUCTION SEALANTS

The construction sealants can be classified in two main categories: acid/

nonacid and high modulous/low modulous. (Two part compounds have been

neglected; narrow joints are assumed.) Acid types liberate acetic acid during

curing and will corrode copper and certain other substrates, and will react with

salt residues from neoprene. Hazardous levels of exposure to acetic vapors set

by OSHA are 10 ppm. Nonacid types liberate alcohol and have wide substrate

compatibility. High modulous sealants have greater strength but allow only ~25%

movement with respect to joint width. Low modulous sealants are as much as 50%

weaker but offer as much as +50% movement with respect to joint width.

Both General Electric and Dow manufacture silicone, but the GE product names are

used here to donate the different types available. The GE 1200 series is a high

modulous acetoxy (acid) standard grade sealant used in conventional glue-on

glazing systems and can be used as well as for attaching modules to the frame.

Its high strength makes it attractive, but suitable substrates must be found or

proper primers chosen to coat difficult-to-bond surfaces to develop proper

adhesion. Exposure to copper must be avoided. It develops a tack-free surface

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in 5 to 10 minutes and cures in 24 hours. The 2000 series is a low modulous

alkoxy (nonacid) sealant whose strength may be sufficient for our purposes. It

has wide substrate capability, greater joint movement, and is noncorrosive. It

develops a tack-free surface in 4 hours and cures in 2 days. The 2400 series is

similar in chemistry to the 1200 but has a lower modulous.

The RTV 100 series is nearly identical to the 1200 product, but is more expen­

sive. The RTV-116 is a low odor noncorrosive silicone rubber that is roughly

equivalent to the 2000 series construction sealant. All of these sealants have

joint width limitations in the neighborhood of 3/8" and cannot be used in

totally confined spaces because contact with air is required for curing.

"SNOW-FENCE" FRAMING SYSTEM

The support frame design is a radical concept that uses manufacturing processes

to reduce on-site labor. In the factory the entire framing system is pre-assem­

bled into a large mat- or net-like structure. This grid has nine stiff wood,

aluminum or steel rails spaced parallel at the module width. Flexible metal

tapes, approximately 2" wide, are connected to the rails perpendicularly at the

module length to form a grid. The framework is thus pre-spaced for installation

on site. This stiff/flexible mat is then rolled up like a snow fence. Two 16

foot bundles can be rolled out on a roof to support one 5 KW array. A roll of

this pre-assembled framework is carried to the ridge of the roof in a direct

mount application. The stiff channels run horizontally across the roof. The

top rail is attached in place parallel to the ridge and then the bundle is

allowed to uncoil by rolling down to the eaves. The grid or mat is thus loosely

set in place before attaching it to the roof. The grid is squared against a

side rail and tacked in place. To insure that the channels are all set at the

proper distance, the flexible tape vertical members are pulled to their maximum

length and then tacked at the bottom. (The tape should not stretch so as to

distort the framing dimensions.) When satisfied that the grid is well placed,

the worlonen mechanically fasten the stiff rails to the plywood surface.

Resilient stops attached to the rails in the factory, prevent the modules from

sliding off the grid until the silicone develops sufficient adhesion. The

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vertically running metal tape acts both as a spacer and also as a backing

material for the sealing of the vertical joints between the adjacent panels.

The tape is crowned and when rolled out can span without sagging; it fits tight

against the underside of the two glass edges at the vertical joints.

The tape members also enhance alignment of the grid because a limited moment

connection could be formed at its jointure to the rails and thus be pre-squared

as it is uncoiled. Only minor adjustments then need be made to produce a truly

square grid pattern.

"METHODS" FOR CREATING SNOW-FENCE SUPPORT FRAME

The flexible metal tape which permits the support frame to be coiled for easy

shipping and quick installation is central to the concept. The rails, however,

can be formed from a number of materials either off the shelf or completely

designed and developed. Three suitable materials for this application are wood,

aluminum and steel. The flexible metal tape can attach to all three either by

welding or mechanical fastening. The processes and material necessary for

manufacturing each type of support frame for ease of reference is known as the

"wood method", the "aluminum method" and the "steel method". The wood method is

preferred for reasons outlined in the manufacturing, installation, and pricing

information and a more detailed description is included here. Brief notes on

the possibilities in aluminum and steel follow that.

WOOD METHOD

The use of wooden horizontal rails instead of metal ones can be justified for

several reasons. First, it perfectly integrates with the materials and methods

of single family residential construction. Hammers and nails are adequate for

installation; no special tools or fasteners are required. With such an utterly

familiar material and attachment method, the installation procedure is quite

clear and learned quickly by on-site labor.

Since wood is easily shaped and cut, receives fasteners with ease, and anchors

with substantial holding power, only low-cost capital equipment is needed for

assembly steps in the factory. For instance, all fastening in this method is

accomplished with a stapling gun and screw driver.

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Wood surfaces are not adequate substrates for silicone adhesive/sealants and

must be modified by priming or cladding with a suitable substrate material.

"Wet" methods and materials (plaster, masonry, and concrete) have all but

disappeared from manufactured housing product assembly and installation routines

for obvious reasons. Therefore, a decision to clad the wooden rails with the

same metal tape as the vertical members rather than coating with a liquid

priming agent is a justifiable step in the right direction, despite higher

material costs than paint. Furthermore, the same spirit of easy wood

construction extends to the tape which can be readily cut with household

scissors (yet has extremely high tensile strength). Once attached to the wood

rail (periodically stapled), it provides an excellent surface for adhesion to

the silicone.

The cladding also provides an opportunity for improved joint design that the

aluminum and steel methods cannot achieve as readily and inexpensively. The

substrate cladding can offer an additional cushioning layer that can help

relieve localized streses and dimensional variations in the framing system and

also uniformly distribute loads caused by snow or wind uplift.

The preferable method retains the "flexible fin" concept introduced by BHKRA in

the first phase of the Integrated Array program and is depicted in Figure I.

Whereas the vertical metal tapes are affixed to the rails in their "crowned"

position, the same tape material clads the wooden rail in its inverted "trough"

position, with its surface rising away from the stapled center to a height of

approximately 1/8" - 5/32" from the surface of the wood. This configuration may

prove ideal for supporting the glass module while not completely deflecting the

fin to "hard" bearing at the wood surface.

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A simple test has shown that the fin will require a uniformly distributed load

of as much as 12 pounds per linear foot to flatten it. Since each module (with

the two-sided support) has approximately 8 feet of perimeter bearing, a downward

pressure of 96# is required for full deflection. Given a module weight of

approximately 3.864#/ft.2, a 35# module yields 61 total pounds or 6.8#/ft.2

of "spring" for handling wind and snow loads before flattening to "hard" bearing

(on resilient spacers). This spring action may stiffen considerably beyond

10#/ft.2 when the silicone infill ties the interior joint surfaces together.

The resilience of the spacer at the edge of the module is a third actor in the

cushioning system. Thus, the flexibility or resilience of 1) the fin, 2) the

silicone, and 3) the edge spacer provide a pillow against thermal expansion,

wind and snow loads, and out of plane deviations along the rail length. As

further experiments proceed, it may be shown that the resilient spacers are

redundant and may be eliminated because the crowned tape still permits adequate

free volume between it and the glass it supports. In other words, it may

improve the strength of the joint by reducing the volume of sealant needed, thus

improving its contact surface-to-volume ratio.

Fl I

The use of these shelf-ready products and simple methods can forego engineering

of a new rolled or composite rail section and the coordination with material

suppliers and assemblers that prototype development entails, while still

retaining the general features of the original "flexible fin" concept. The

elegance of the system is thus extended because the proof-of-concept can be

demonstrated in the BHKRA or JPL shop. Besides the materials lists of modules,

wood rails, metal tape, staples, nails, silicone adhesive, and flashing; only

the following equipment is needed to assemble and install the support frame and

modules at bench scale.

1. Scissors 10. Chalk line

2. Hand saw 11. Tape measure

3. Stapling gun 12. Wooden shims

4. Hannner and holster 13. Utility knife

5. Twine for tying bundle 14. Caulking gun

6. Nail apron 15. Pencil

7. Metal break for flashing 16. Gloves

8. Tin snips 17. Tools related to electrical wiring

9. Ladder (depending on height 18. Paper towels for clean-up

of mock-up)

Despite the advantages of the wood method, several potential problems should be

anticipated to insure the success of the system. Wood is not as dimensionally

stable as aluminum or steel, and therefore, the members to be used in a support

frame must be properly dried and carefully selected to reduce the possibility of

warping, checking, or splitting before, during, or after installation. This is

a materials and quality control problem that is reflected in the price of $0.55

per foot. The wood method, as presently conceived, is clad with the flexible

metal tape in the "trough" position to retain the flexible fin concept. The

extreme edge of the fin, elevated from the top surface of the rail, may be

vulnerable to some damage in the field if subjected to considerable foot

traffic. The edge on the "upside" of the rail is most vulnerable because that

is the edge on which the workmen place their feet for climbing upwardly on the

roof. Whether this turns out to be a significant problem remains to be seen

through mock-up testing and field experience. Other than these solvable issues,

the wood method is an utterly simple, irreducible configuration of materials and

manufacturing methods intended to competently support a PV array that heretofore

has been mounted with significantly more complex hardware.

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ALUMINUM METHOD

The aluminum method simply substitutes rectangular aluminum tubes for the wooden

rails previously discussed. One and one-half by two inch tubular sections can

be purchased off-the-shelf for incorporation into the support frame. An

automated assembly process can be created similar to the wood method but a few

extra machine steps are required for fabrication. For instance, the aluminum

channel should be slotted on the top and bottom to receive both a field anchor

and a resilient stop for temporarily supporting glass modules. If the modules

are supplied with resilient spacers on the back edges, there is no need for

cladding with flexible metal tape as in the wood method for purposes of creating

a suitable adhesion surface. The anodized aluminum surface is well suited to

receive the silicone. If weight is a critical factor, a drawn aluminum tube

with a 0.047 inch thin wall can be chosen, as its weight is only 0.324 pounds

per foot, approximately half that of the wood. However, drawn tube costs

approximately $5.00 per pound or $1.64 per foot. Extruded aluminum tubing can

be purchased for approximately $1.30 per pound, but can only be extruded in

thicker wall dimensions. A suitable extruded tube for this application would be

one with a 0.125 inch wall thickness but would weight 0.975 pounds per foot and,

therefore, close to $1.30 per foot, more than double the cost of wood and

somewhat heavier. Given these figures, wood still remains the first choice.

STEEL METHOD

Rolled steel sections can substitute for the wood rails in certain applications

but retain some of the disadvantages of aluminum. Holes for connections must be

stamped or drilled and weight may be a problem depending on the wall thickness

chosen. Twenty-gauge material is adequate for this application, but may weigh

as much as 0.9 pounds per linear foot, again somewhat higher than the weight of

the wood rails. It may be purchased, however, for as low as $0.35 a foot.

Thinner gauges may be used but the shape of the section becomes more critical to

reduce the possibility of damage by the tread of workmen. Given all these

factors, it still appears that wood is the best material available for testing

the concept. However, under certain market conditions and certain applications,

the use of steel or aluminum may prove to be useful.

(4)

(5)

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Illuminated (active) surface envelope dimensions and shadowing or view­

angle constraints. The ratio of cell area to module maximum area shall be

provided. For shingle module, area overlapped by adjacent modules is

excluded.

As the photovoltaic module is defined by AIA/RC, the active area for the

module is given as:

Active area* -- 11,695 cm2

Module area -- 12,943 cm2

Active to total ratio -- .904

*Accounts for 2 nnn intercell spacing.

There will be no shadowing or view-angle constraints as the mounting

system has a zero profile angle with the top surface of the array.

The array dimensions are:

Active area -- 49.12 m2

Array area -- 55.49 m2

Active to total ratio -- .885

Equipment grounding configuration, including location, materials and

finishes, and user constraints (e.g., torque limits, surface sealing).

The proposed mounting system does not have exposed metal surfaces. The

metal tape used in the system is coated. The only other metal surface is

the flashing which should not come in contact with any electrically active

parts. The cells and encapsulating system must be held back from the edge

of the glass, thus no electrically active hardware can come in contact

with the metal "snow-fence". If it is felt that the metal parts of this

system must be grounded, a grounding cable could be attached to the metal

tape at the bottom of the array and run to ground.

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(6) A dimensioned cross-sectional view of the encapsulant systems through

cells and interconnects.

As the module was defined by AIA/RC, the following cross-section is

given:

1/8" (3.18 mm) Low Iron Tempered Glass

2 - 0.018" (0.45 mm) layers of EVA

PV cells

1 - 0.005" (0.127 mm) layer of "Crane Glass"

1 - layer of EVA

1 - 0.006" (0.152 mm) layer of polyethylene

It is recommended that the perimeter of the module be clean glass

approximately 3/4" to 1" (19.05 mm to 25.4 mm) edge of glass to

encapsulation.

(7) Dimensioned view(s) of both front and back contact cell-to-cell inter­

connect attachment geometry including strain-relief provisions.

(8)

Cell-to-cell interconnect is given by definition by AIA/RC. Description

of the detail is deferred to AIA/RC.

Electrical performance (P at NOC, V • P at 100 mW/cm2, 25°C) avg no' p

As the module is defined by AIA/RC, the following electrical character­

istics are given at 25°C:

Power -- 133.5 Wat peak

Voltage -- 18.8 Vat peak power

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(9)

Amperage -- 7.1 a at peak power

Open Circuit Voltage -- 23.79 V

Short Circuit Current -- 8.16 a

NOCT

The module as given has an NOCT of 49°C. The array is expected to operate

at a slightly higher NOCT when mounted in a direct application.

(10) Maximum weight.

The module as given weighs 54 pounds.

The array mounting hardware weights are detailed as follows:

Weight of Mounting Hardware

Part No.* Wt. Per Part No. of Pieces Total

WdHR-1 25. 5841 7 179.07 WdSR-1 11.09 2 22.17 HMT-1 .893 7 6.25 VMT-1 .387 6 2.322 RS-1 84 1.00 Staples 2260 5.00 Silicone Jt. f!l 3.84 5 19.20 Silicone Jt. ff2 5.547 1 5.547 Silicone Jt. 113 6 2.31 Metal Flashing 1 3.00 Nails 200 10.00

Total weight of all hardware 255. 8711

*See "Materials List"

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Total weight of "snowfence" bundles

(One array contains two bundles)

Part No.

WdHR-1 WdSR-1 HMT-1 VMT-1 RS-1 Staples Carton

2 bundles

1 bundle

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2 man crew must lift

Total

179.07 22 .17 6.25 2.32 1.00 5.00 3.00

218. 814~

109 .4Hf

54. 70/f per man

A typical roll of roofing felt weights 60 lbs. and is ordinarily carried by one man up a ladder onto a roof.

(11) Detail and location of manufacturer's identification label and, if

applicable, caution labels.

(12)

As module is defined by AIA/RC, the manufacturer has already located a

label. However, as the mounting system utilizes modules without frames,

it will be necessary for the label to be affixed to the module back

surface.

Installation and interconnection details, including typical system

mechanical, electrical and configuration constraints, for a representative

5-KW, grid-connected single-family residential application.

The following is a detailed description of the proposed installation

scenario for the "glue-on" concept. Following the description is a

breakdown of the man-power requirements.

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Installation Procedure

SET UP

A maximum of two glaziers and two laborers are necessary to install this 5 KW

array. It is assumed that the installation is subcontracted to a PV array

installer and the crew arrives at the building site with 64 modules, two

packages containing the mounting frame, approximately 4 gallons of adhesive/

sealant, flashing, nails, and miscellaneous tools and equipment required to

complete the job in one day.

The south facing roof surface to receive the array 1s the approximate size of

the PV array, has one layer of 30# felt, and is free of debris. One 2 x 2

blocking member the entire length of the roof has been set at the ridge by the

General Contractor to receive the ridge vent. This member acts as a guide

against which the top rail of the mounting frame is set.

Two ladders are raised at convenient points at the eaves. While the mounting

frame packages are being unloaded by the two laborers, the crew leader and the

other glazier mount the roof to check its overall dimensions, squareness, and

evenness. If the 2 x 2 blocking is out of square, the error is corrected with a

new beginning line snapped with a chalk line. Lack of squareness can also be

corrected with the side rail placement that is set at the extreme slant edge of

the roof.

MOUNTING FRAME INSTALLATION

Satisfied that the roof surface can receive the array, the first side rail is

called and nailed in place, square the with ridge. The first frame bundle 1s

then called by the crew leader. This bundle, approximately 16' long and still

packaged (but already opened to retrieve its side rail) 1s carried to the roof

by the two laborers on two ladders where it is received by the two glaziers. It

is carried to the ridge with the help of the laborers, unpackaged, and the

carton thrown to the ground. Once unpackaged and positioned, the top rail is

placed against the 2 x 2 or chalk line by the crew leader and other glazier who

tack it in place from kneeling positions immediately across the ridge on the

north face. Concurrently, the two laborers support the bundle on the downside

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to prevent its uncoiling. Once the top rail is secure, the laborers allow the

bundle to slowly uncoil, proceeding down the slope of the roof toward the eaves

and their ladders. To facilitate this routine, hemp twine may be rolled into

the bundle at the factory to allow the glaziers a hand in letting the bundle

down the roof. When the bundle is nearly rolled out, the laborers take posi­

tions on the ladders at the eave. With supervision from the crew leader and

glazier, who are now near the eaves on the free side of the slope, the laborers

square the last rail against the roof edge and eave. A slight tug on the last

rail will fully extend the frame to take out any slack. Once squared and fully

extended, the last rail is tacked in place sufficiently to be used as a typical

roof "kicker". This "positioning and tacking" routine may invovle the reposi­

tioning of the ladders to ensure squareness and full extension without slack.

One ladder may be positioned against the gable end of the house for sighting

along the rails and guaranteeing tight fit of the horizontal rails against the

side rail. The horizontal rails are then nailed in place at their ends near the

side rail and at the first set of rail/tape intersections proceeding from the

bottom rail to the top. Once these nails are in, the secure rail ends act as a

ladder for easy traveling up and down the slant edge of the roof.

The next procedure is a quality control routine to ensure planar trueness of the

mounting frame. Two strings are tightly stretched along the full diagonal

lengths of the frame to form a large "X". Inspection along the strings will

determine the need for shinnning with typical wood shims (used at all construc­

tion sites). Since inspection for trueness probably will involve a need to be

"inside" the frame as well as along its perimeter, a "path" up through the

middle of the array should be created starting with a tack (nail head not fully

driven) in the middle of the bottom rail and proceeding with tacks up to the top

rail. Again, the tacked-in rails double as kickers typical in any roofing

installation in the 6 & 12 to 12 & 12 range. This is known as "nailing yourself

in" and is always practiced during the placement of roofing felts on steeper

roofs. The first few roofing nails are driven vertically along the width of the

horizontally rolled-out felt rather than all along the top edge. If not, the

felt may tear underneath the roofer's feet, especially in hot weather, causing

him to disappear below the eaves. In the fastening of the mounting frame, this

routine is not so much a matter of safety (the felts are already nailed) but one

of quality control. If a workman slipped down against a free rail, it would

prevent a fall but may damage a rail/tape joint. Tacking in the middle of the

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array is quite acceptable during the correction out-of-plane depressions. If a

rail needs to be slightly raised, it can be pryed and then a shim slipped

underneath before the nail is driven home. Such routines are practiced as a

matter of course in construction and point to the benefit and ease of working

with wood. After the frame has been trued to a plane with shims, if necessary,

the frame is "nailed up" from bottom to top to complete its installation. The

second bundle for the second half of the roof is then installed with the same

procedures taking care to end match the rails in the middle of the roof.

The benefits of the nailed-down horizontal rails over entire roof is obvious.

Since traffic up and down a roof surface can be considerable, such footing for

the workman will improve safety and speed installation. Traffic laterally

across the roof is less safe because of the metal tape running over top the

rails. In this regard, the crew leader should restrict lateral traffic to the

minimum required.

FLASHING

The next installation routine is the placement of flashing. The first piece is

nailed to the bottom rail. The side rails are covered next, then the top rail.

The nails are driven along lines that will be covered by the silicone adhesive/­

sealant. The mounting frame is now ready to receive the modules.

MODULE INSTALLATION

First, appropriate sized holes are drilled through the roof sheathing at the

corners of the roof to allow the bus wires to lead to the power conditioner

inside the building. Then, the top horizontal row of modules to be placed

nearest the ridge are brought to the roof one at a time. Setting, positioning,

and electrical hook up is done "dry". Glue-down with adhesive/sealant follows

behind. One laborer works on the ground, ("ground" laborer) and climbs the

ladder, bringing each unpackaged, unframed module to the top of the ladder where

it is received by the other laborer, ("roof" laborer) who brings it to a glazier

who "rough sets" it on the frame (against the resilient stops) allowing hand

space between it and the adjacent module to the left or right. He "quick­

connects" it to the adjacent module, repositions it in its final resting place,

leaving a 3/8" space at the vertical joint over the vertical metal tape running

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immediately underneath the parallel edges of the glass. He then hits this

vertical joint (#3 joint) with the caulking gun to create the weatherseal. This

joint, which receives less than 1/5 the volume of silicone as does the major

horizontals (Ill joints), will probably be best done by the "connecting" glazier.

The other glazier's main occupation is working the gun at the horizontal joints

which receive .42 gallons with each pass across the roof. Since only one pass

is required for each horizontal joint, the "gluing" glazier reaches across the

2'-0"+ width of "dry mounted" modules that have just been connected. In other

words, he does not begin the first major horizontal joint until the first

modules of the second horizontal row have been placed. During the placement of

the first row, he has been busy with the top perimeter joint (#2 joint)

following behind the "connecting" glazier.

The division of labor between the four workmen appears to be quite well balanced

in time. The least hurried of men is likely to be the second laborer on the

roof who can fill his "spare" moments supplying the gluing glazier if necessary,

or helping the "connecting" glazier with positioning. While the connecting

glazier is executing the #3 joints, the roof laborer receives the next module

from the ground laborer.

The subsequent installation proceeds with the same repetitive routines, 8

modules to a row. During the placement of the next-to-the-last row, the roof

will become crowded and the roof laborer should descend to begin the clean-up.

The last row at the eaves is the most tedious to install and probably will

require a third ladder for greatest efficiency. It is executed in the following

manner.

FINAL ROW INSTALLATION

With the "dry-mounting" of the last module in the next-to-the-last row, the

connecting glazier descends to the ground. Only the gluing glazier remains on

the roof to finish the next-to-the-last #1 horizontal joint. The clean-up man,

meanwhile, places a third ladder for the gluing glazier's eventual descent.

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The connecting glazier and ground laborer (who has been carrying modules most of

the afternoon) now must work closely together off two ladders. These two

ladders are placed at the corner of the roof; one at the eave, the other immedi­

ately around the corner of the house on •the gable end. The glazier takes the

gable end ladder to the top. The laborer takes the eave ladder and brings the

first module up. The glazier takes one end and the two men set the module in

place. The laborer descends, moves his ladder over 4 feet and goes for the #2

module. Meanwhile, the glazier applies a #2 silicone joint at the side rail,

then descends and moves his ladder around to the eave 4' from the end of the

building and 4' away from the other ladder. While on the ground he may help the

laborer carry up the ffo2 module. It is "rough set" by both, quick connected by

the glazier and then positioned by both.

The laborer descends and moves his ladder 4' over and goes for the next module

while the glazier executes 4f3 vertical silicone joint. The glazier d_escends,

moves his ladder over 4 feet, by which time the laborer has arrived with the

next module. Both ascend and repeat the same routine. Presently, the gluing

glazier has finished the next-to-the-last #1 horizontal joint and has descended.

He and the clean-up man carry his ladder to the #1 dry-mounted module and then

the last major horizontal joint and the perimeter joint at the bottom rail is

begun.

When the last module has been dry mounted, the laborer finally descends to help

with clean up and the connecting glazier remains to help the gluing glazier

finish up; both successively moving their ladders from the ends toward the

middle of the last row. At this point, clean up should be nearing completion.

While the last of the silicone is placed, the glaziers.descend, the guns are

packed, and the ladders stowed on the truck. Final connections to the power

conditioner is by the Electrical Contractor.

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(13) Installation equipment of tools required, if any.

Conventional tools found on a residential job site are required for the

installation of the array. The one deviation is a special nozzle for the

caulking gun as depicted in the following figure:

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Mock-up Description

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ABSTRACT

A mock-up of the mounting frame concept has been carried out. The two main features of the concept have been simulated: the interfacing module support frame ("snowfence" bundle) and the module attachment method, an adhesive bond using typical silicone construction adhesive/sealant. Within the bounds of a bench-scale experiment, both of these features have been successfully proven as a simple, low-cost method for attaching frameless photovoltaic modules to the roofs of single-family dwellings.

In demonstrating the overall concept, it has become evident that specific aspects of the installation procedure will require additional refinement. These aspects are more confined to the categories of installation technique, tool refinement, and the skill of the installation crew. Although the need for improved techniques is conspicuous, the kit of materials used for the support frame and bonding method remains unabridged. Subsequent optimization may uncover a need for slight modifications in material choice, subcomponent shape or connecting hardware.

DESCRIPTION OF MOCK-UP COMPONENTS

Roof Surface

A mock roof surface was constructed in the BHKRA workshop with materials and procedures typically used in single-family dwellings. The structure was assembled using 2x4's and 2x6's to receive 1/2 inch thick plywood covering a sloping area of approximately 8' by 16' large enough to handle a 9 module array using 31-3/4" x 61-3/4" modules. The slope was set at 8 and 12 with 2x6's supporting the plywood surface at 2 foot centers. Two by fours set 2 feet on center vertically supported the ridge. To ensure complete stability, the bottom of the slope (the eaves) were tied by 2x4's running horizontally back to the vertical members supporting the ridge. Thus, a triangulated, rigid support structure, approximately 6' at its highest point, was created to receive the support frame.

Support Frame ("Snowfence" Bundle)

The mock-up of the support frame was carried out using actual materials intended for future installations in the housing markets. Four 1-1/2" by 2" x 16' wooden rails were cut from construction grade cedar boards. Earlier thinking during concept development anticipated the need to use select grade lumber for this application; however, the construction grade cedar with tight knots appeared to be dimensionally stable and, therefore, quite adequate for use in this custom-made assembly. The second main component of the mounting frame, the 2 inch aluminum metal strip with 3/16 inch crown was acquired from a Venetian blind component supplier. An electric hand stapler using 9/16 inch staples was rented for attaching the metal tape to the wooden rails.

Even though the cedar rails were relatively free of warps or twists, they were set in jiggs precisely spaced and squared in order to assure precise attachment of the tape, first on top of each rail and then perpendicularly across the rows tying each rail together. The cladding of the cedar rails was accomplished first by attaching the tape on top of the rail at 18 inch intervals with the

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staple gun and then making a second pass with the gun stapling at 2 inch intervals along the length of the rail. The cladding tape was first tacked into place along the length of the rail because it was felt that any midway correction that needed to take place in the course of a straight away stapling routine may have resulted in some distortion of the tape lip as the correction (realignment) was made. Since the wooden rails were fairly straight to begin with, it is not fully known whether the cladding tape will hold an otherwise warped board in a straight line after it is removed from the jig. It was discovered, however, that the clad cedar material is not so stiff and unyielding as to disallow minor straightening of the rails once they are on the roof by "pulling out the bends" and then nailing in place once they have been straightened.

The flexible tape running perpendicular to the rails, at intervals equaling the module lengths, form the so called vertical joints and thus allow the framework to be rolled up, packaged, delivered to the site, unpacked, and then unrolled onto the roof. These flexible tape members were precisely spaced at module lengths, allowing a 3/8 inch space between modules to fall directly onto the center of the tape. Where the flexible tape and the metal clad rails intersected, the flexible tape was "stitched" to the wooden rail with approximatley 10 staples. Once the flexible type members were in place, the support frame was complete and ready to be released from the jigs. Up to this point, the entire undertaking had been problem-free.

During the first attempt to roll up the four-rail support framework, it was noted that the fourth rail could not be made to meet rail-on-rail with the previous three as it was coiled in a bundle. This is quite obviously due to the increasing diameter of the coil in opposition to the regular spacing of the rail. Solution of this problem by further experimentation was delayed in favor of preserving the framework for the actual mounting of glass panes simulating photovoltaic modules. Solving the roll up problem was to be carried out using a support frame with considerably shorter rails but having the exact number of rails as in any typical full-size installation. In this way, the position of all the rails within the bundle from the first rail to the last could be observed during the coiling and uncoiling routine.

Support Frame Installation

The completed support frame assembly, with three of the four rails coiled, was lifted into the uppermost portion of the mock roof surface. The top rail was tacked in place as might be typically done in a future "real world" installation. The other three rails were carefully uncoiled down along the roof surface. The bundle was not allow to uncoil under its own weight, but was held above the roof surface and turned over and over with constant support of the diminishing coiled portion.

The first major function of the "snowfence", the capacity for coiling, needed refinement; but once the support frame had been rolled out on the roof, its second major function, providing a prespaced grid, seemed to work quite adequately. Since the flexible metal tape along the vertical joints is non-stretchable, each individual rail is distributed down along the roof surface at its intended location. Since the flexible vertical tape forms a limited moment connection at the rail, any shift in a rail along its length will produce

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a telltale twist in the tape. When the rail is moved back into position (it is unable to shift very far), the tape flattens and, therefore, straightness and squareness is indicated within the grid work. More subtle shifts in the rail can be observed by sighting down along the length of the flexible vertical tape. Any slightly deviant rail can be lightly tapped back into alignment. Before each of the rails was nailed in place, it was checked and rechecked with respect to its squareness against the side rails and also the spacing of the ends of the rails which were unsupported or "unprespaced" by vertical metal tape. Since the array was only three by three with the module lengths running horizontally, only two "interior" vertical joints occur in this partial array. Thus, the ends of the rails were cantilevered from the vertical metal tape joints. In this condition, the rails had a slight tendency to sag at their ends. They were quite easily made straight by slightly pulling them up and nailing them in place.

After the rail members were satisfactorily straightened and squared against the side rails, the frame was nailed to the plywood surface with twelve 12d box nails at two feet on center.

Installation of Resilient Stops

Conical shaped rubber stops approximately 5/8" in diameter with holes in their centers were purchased at a local hardware store to be modified for use as resilient stops to support the glass panels prior to gluing with silicone adhesive. Several different stop designs were fabricated by carving the standard rubber stop. Each new design was an attempt to make the resilient stops a less obtrusive feature in the joint between PV modules. The holes at the centers of the stops were large enough to receive either an 8d common nail or a 6d finishing nail. Typically, the rubber stops had to be made less than 3/8" in width in order not to obstruct the placement of the PV module immediately downslope from it. However, the size of the resilient stops was noted to be an immediate problem along the path of the silicone joint. The design of these stops would cause interference during the gluing routine at two points along each module. It seemed certain that a more acceptable solution had to be devised.

The main problem of interference with these particular stop designs with rubber heads was that any special nozzle used in the gluing routine would probably have a guide on the heel of the nozzle which fit down into the space between two adjacent modules to help guide the placement of the silicone material. This guide on the heel of the nozzle would obviously bump into each resilient stop, causing an unacceptable interruption in the gluing procedure. A very thin profile stop had to be designed which would allow the guide on the nozzle to bypass the stop. Nevertheless, the rubber stops were installed to see how they would work. Several of the glass panels, 3/16" by 31-3/4" by 61-3/4" were set in place on the slope surface using the rubber stops to train them. As anticipated, sealing around the rubber head of the stop was a problem. The stops had to be redesigned.

In concept, the stops should be a very thin metal tab, its flat side running parallel with the bottom edge of the glass, whose height rises far enough to engage the edge thickness of the glass but not so high as to protrude above the glass surface. The actual hardware chosen to accomplish this were thin, razor

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sharp replacement blades for an utility knife. More specifically, the blades were for an Exacto Knife and were approximately 1/2" wide by 1-1/2" long. Because these blades are razor sharp, they are very easily driven through the metal tape and the cedar rails.

Several packets of these blades were purchased at a local office supply store and used to replace the rubber-style stops over most of the array where glass panels had not already been set in place. These flat metal stops, two per module, set at the fifth point along the bottom edge work well to support the glass, but have only one drawback. Because of their slim profile, they are difficult to see and should be marked with some color so that workmen can avoid stepping on them.

DRY-MOUNTING THE GLASS MODULES

Glass Size

Nine panes of glass, 31-3/4" x 61-3/4" x 3/16" thick were ordered from a local supplier and used to simulate PV modules of the same size. Expense and availability ruled out the use of tempered glass, so ordinary glass was used instead. Eighth-inch double strength glass, typically available in 30" x 60" panes, seemed a bit too fragile for our purposes. Therefore, it was decided that 3/16" thick glass would be used because it appeared to be substantially stronger and subsequently less dangerous than the 1/8" double strength. The size and weight of these glass panels make them easy enough for one man to carry along level ground, especially if large handled suction cups are used when picking up, carrying and setting the glass in place. The suction cups are particularly useful when it comes to setting the glass in place on the sloped surface. The glass is held in a more or less vertical position and its bottom edge is set against the up-slope side of the thin metal stops. Without the use. of the suction cups, one's fingers have a tendency to become trapped between the bottom edge of the glass and the clad wooden rail. Although carrying the glass across level ground appears to be no problem, carrying them up the sloped surface of a roof is a bit more difficult. The difficulty wholly arises from the fact that the module width, which sets the spacing of the horizontal rails, is set at the upper limit for comfort in climbing up the roof slope. That is to say, the 32" st ride between rails is quite wide and has to be taken slowly and carefully. If the module width was set at 2 feet, the trip up the slope with a module would be far more comfortable. It is also noted later in this report that the module width is at the upper limit of comfort for reaching across with a caulking gun and gluing a line of two adjacent modules in place.

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CHARACTERISTICS OF THE METAL CLADDING ON THE WOODEN RAILS

Flexible Fin Concept

The flexible metal tape stapled to the horizontal wooden rails has two functions. The first is to create a suitable substrate for adhesion to the silicone which adheres to the bottom side of the module edge to hold it permanently in place. The second function is to create a slightly elevated flexible fin which gives some cushion to the glass module during installation which is also not so depressed by the weight of the module as to eliminate space between it and the bottom side of the glass. This void between the rail and the underside of the glass is to be partially filled with silicone during the gluing process to create adequate contact area for the silicone adhesive to do its work. In this regard, the crowned metal tape seems to work well in setti~g up the geometry of the joint space for subsequent application of silicone adhesive/sealant.

Vulnerability of the Tape During Module Installation

During the design phase it was anticipated that the up-slope edge of the cladding tape of the horizontal rails might be vulnerable to damage due to the tread of workmen using the horizontal rails as kickers for movement up and down the roof slope. As anticipated, the edge of the tape does have a tendency to become creased if one is not careful as they walk upon the rails. The chief reason for this is that the tape is the same width as the wooden rail beneath it. If the wooden rail were wider or the tape narrower, this concern could be alleviated somewhat. These occasional creases, however, are not ruinous to the horizontal members. When they occur, they can be eliminated by tapping them out with a hannner. Some evidence of the original damage is still retained in the repaired area of the tape, but this in no way compromises the installation of a PV module in that area of the horizontal rail. The flexible fin of the tape still seems to compress quite uniformly under the weight of the module. To work best, the metal tape probably should be 1-1/2" wide rather than 2" wide. The array packing factor would be enhanced somewhat and the edge of the tape which actually supports the module would be kept as near the edge of the module as possible, thus minimizing the possibility of abraiding the substrate or cutting into the cell interconnects, thus causing a short in the system. The horizontal wooden rail underneath the 1-1/2" tape could be slightly wider at (approximately 1-3/4") to help alleviate the vulnerability of the tape edge as mentioned before. However, 1-1/2" metal tape is not available from Venetian blind component suppliers because the blinds are sold only in l" and 2" sizes.

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ADHESIVE BONDING WITH SILICON CONSTRUCTION ADHESIVE SEALANT

Modified Nozzle Design

Because of the simplicity of design and materials of the support frame, its behavior at the scale of a mock-up was fairly well anticipated in the early phases of design. That is to say, the present facts of the mock-up closely matched earlier faith in the design. More questions surrounded the application of the silicone; and this became one area of investigation where a series of experiments had to be carried out. It was known in the design phase that the application of silicone had to be done through a specially designed nozzle. The typical nozzles of all prepacked sealant tubes, any caulking gun using sealant from large voltm1e containers, suffer from three deficiencies. First, the nozzle opening is too narrow for the joint width used in this system. Secondly, the silicone must be forced underneath the underside surfaces of the modules at the joint to create sufficient contact area. This seems to be only accomplished by providing a pressure plate or cap over the joint that promotes the forcing of silicone underneath the glass rather than allowing it to extrude in a random fashion up and out through the joint face. Thirdly, it had been suggested by some reviewers of the concept that the silicone joint should extend above the surface of the glass and over the edges of the glass modules so as to create a protective strip of silicone approximately 1/16" thick and extending at least 1/8" over the edges of the modules to create a protective covering for the vulnerable edge of the tempered glass cover plate typically used in PV module fabrication. In effect, the silicone must be continually deposited in the joint, forced underneath the glass and then tooled as the nozzle moves along in such a fashion that the protective cap is extruded neatly from the toe of the nozzle. These requirements can only be satisfied with a redesigned nozzle.

The first rather straightforward nozzle design was mocked-up in wood and then later machined from a block of aluminum because it appeared to have promise. This simple nozzle has four main characteristics. It is wide enough to create a pressure plate in order to force the silicone underneath the glass; it has a central portal through which the silicone is deposited into the joint; it has a single sled centered on the heel side of the nozzle which fits down between two adjacent modules to act as a guide while moving along the horizontal joint, and the toe of the nozzle has a grooved portion which allows the protective silicone "over-strip" to be extruded through it. This nozzle design works well under certain conditions. The silicone must be delivered through the portal at a fairly constant rate and pressure and the nozzle must be allowed to move along the joint that coordinates with the adequate deposition of silicone and the neatness of the protective "over-strip" extrusion. If the guide on the bottom side of the nozzle runs aground on a staple, nail head, or resilient stop, the steady motion is interrupted and coordination lost. Moving in a halting fashion along the length of the joint has a great tendency to create blemishes due to stopping and starting. If the so called pressure plate of the nozzle is lifted up and away from the surface of the glass during the operation, silicone may extrude between it and the top surface of the glass thus creating a smear.

Another factor which affects the smooth operation of the caulking gun and nozzle is the uncomfortable 32" reach up across the module to the horizontal joint between two rows of modules. Perhaps this can be alleviated by a swivel joint between the caulking gun and the nozzle which allows the caulking gun to swing down toward the body in a more comfortable position for operation. Reducing the

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module width to 2' would greatly facilitate the application of silicone. As noted earlier, it would also significantly enhance ·the transport of modules up the roof by reducing the stride between horizontal rails •

Several changes in nozzle design and application procedure, beside those already mentioned, would greatly improve the application, contact area, and appearance of the finished joint. First of all, the use of a pneumatic caulking gun would assure a constant pressure and volume of silicone material. Secondly, a flexible, clear plastic nozzle, much less bulky than the aluminum one, may offer a significant improvement in technique. A more sophisticated design which deposits silicone from portals located underneath the glass and at the same time forms the protective silicone strip could also be designed and tested. These possibilities are recorded in sketches that appear at the end of this section.

The modified nozzle design used for th mock-up was conceived chiefly for use on the horizontal joints which do the work of bonding the glass to the support frame. The nozzle can be used on the vertical joints although there is no importance attached to gaining contact area on the bottom side of the glass at the vertical joint. The same protective strip of silicone which covers the top of the module edges is still a requirement for the vertical joint, therefore, the nozzle is still able to be used on a vertical joint. The joints along the perimeter (top, side and bottom) cannot be done using the special nozzle, therefore, they were executed using the typical nozzle ordinarily attached to a tube of silicone. It seemed that adequate silicone could be forced underneath the glass, but at these edge conditions a protective covering over the edge was difficult to obtain using a conventional nozzle. Some protection could be created by an edge joint which built up and cantilevered over the edge of the glass. Despite this phenomenon, due to slightly excessive amounts of silicone, this seems a precarious way to protect the edge of the glass. Besides, application of the silicone does not always result in a protective "overhang" of silicone being created. In a slight majority of the joint lengths the height of the silicone joint only matched the height of the glass on the perimeters, thus offering little protection to the glass edge. Modifications to the edge sealing routine were carried out. These mainly included the use of a notched nozzle to try to create a protective lip of silicone around the perimeter edge of the modules similar to that done with the interior joints. Success was marginal using this technique and it was also felt that notching of the typical plastic nozzle by carving with a knife was a too precise and elaborate procedure to be carried out in the field. Nozzle designs which could possibly solve the perimeter silicone edge seal appear also at the end of this section.

Silicone Application Technique

Improvements in all the silicone joints can be achieved in two ways. An "idiot-proof" nozzle can be designed to ensure the accurate formation of the joint. Or a reasonable nozzle design can be put in the hands of a skilled operator.

The former would be a more sophisticated device with under-glass portals in combination with an over-glass lip to extrude the protective silicone strip. The latter may be a simpler affair made from injection molded plastic and probably disposable. Despite the level of sophistication of the nozzle design, it would probably take any operator a bit of practice to "catch on" to the proper technique of application.

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Inspection for "Leaks"

After the joints had cured and inspection was made along that length to uncover any irregularities that may be the source of water intrusion. Only two sites were identified which could be the source of possible leaks. It appeared that these were the result of a start-and-stop motion of the caulking gun. Although the cross joints in the middle of the array appear to be reasonably watertight, some skill will be required in executing these joints to ensure complete watertightness and satifactory appearance. Further developments in nozzle design along with the use of a pneumatic caulking gun will cause these defective features to disappear from future real world installations.

Joint Turns

The appearance of the joints on the mock up is less than satisfactory. This dissatifaction arises in the most obvious case of the contrast of the brown silicone against the green metal tape. The pastel color of the metal tape acts as a background to set off irregularities, especially unevenness in the contact area between the underside of the glass and the metal tape. For experimentation purposes, this was a desirable feature; one can more easily study the joint appearance with contrasting colors. However, these effects should be minimized in any future real world installation. It can be accomplished with the use of black or dark brown metal tape, which is available from the suppliers of this material.

Other undesirable joint features are the various blemishes and smears attributed to the start-and-stop operation of the caulking gun. Again, these can be minimized with further nozzle develop. One feature in the joint appearance may be more difficult to eliminate than the gross blemishes just pointed out. Even along lengths of well placed silicone, the protective silicone strip extruded from the toe of the nozzle appears to have an ever present undulation, sometimes subtle and sometimes pronounced. This may be more attributed to the fluid characteristics of the silicone rather than the specific nozzle design.

The start-and-stop operation of the caulking gun is done in two ways and results in two different blemish types. Retracing the joint by "backsliding" or recovering territory which appears to lack adequate silicone, results in a marginal discontinuity of the protective strip. A more obvious blemish is created by physically lifting the nozzle from the joint at a stopping point and then placing the nozzle down to begin again. Unless the operator is particularly skilled in this maneuver, it should be avoided to eliminate risking joint integrity and appearance.

Module Replacement

To remove any particular module, the silicone joints can be easily sliced with a thin razor-like blade attached to a handle. For the sake of demonstration, the thin blade of an inexpensive utility knife was slipped under the edge of the module and sliced through the silicone. A knife with a blade of similar thinness but greater flexibility is required to easily perform this task. It appears that the simplest way to replace a module would be to stand two ladders across the array from the eave to the ridge. These two ladders would be set apart at a distance slightly greater than the lengths of the module to be replaced. Two workmen would ascend these ladders which act as eight ridges, and

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workmen would ascend these ladders which act as eight ridges, and by reaching over a half module length, share the task of cutting the module out of its bed of silicone. The actual slicing away of the joint would take only minutes. Large rubber suction cups would be afixed to the glass so that each man could give a hand in lifting the module out of place. The other hand of the workman would be used to help guide himself down the ladder. Both workmen would walk the module down the ladder to a point in the eaves where scaffolding or other ladders have been placed. The module then can be carried to the ground. If necessary, more of the silicone joint is prepared by slicing away other portions of the joint, depending on the need to "clean it up". The same routine used in cutting out and lowering the module would be used in installing the new one except in opposite sequence. In the case of the module replacement, it may be necessary first of all to place the silicone in the joint first before laying the module in place. The final procedure ultimately would depend on information from subsequent development of the system and practice with full-scale mock ups.

COILING AND UNCOILING THE "SNOWFENCE" BUNDLE

Learning how to properly coil the "snowfence" bundle was carried out as a separate investigation apart from the other components of the mock up. After the original "snowfence" support frame had been pulled from the jigs, just after fabrication, an attempt to coil the frame was carried out. It was found that although the first three rails could be made to stack upon one another as they were coiled, the fourth rail refused to cooperate and to not form a rail to rail juncture during the coiling operation. Simply continuing to coil the bundle without regard to the position of the subsequent rail probably would have resulted in a severe crease in the flexible metal tape. It seemed obvious that the support frame needed some kind of "help" in the coiling process.

Seven short rails were prepared and set at the appropriate distance and tied together with two metal tapes. Seven rails were used, representing a six row array. The first coiling experiment with this new mock up was perfonned using a four inch cardboard carpet tube. The support frame was merely wound upon the tube to see what affects would be caused by this procedure. This method worked surprisingly well. It was found that the rails were fairly well distributed across the tube and that when the support frame was uncoiled, there were only minor creases in the vertical tape that could have used some repair. All in all, the four inch tubes seemed to work fairly well. Next, an eight inch diameter tube was tested to see whether the metal tape can be spared any small creases. However, it was found that eight inch tube gathered all of the rails in a cluster on one side of the tube, rather than distributing them more evenly around the circumference of the tube. The eight inch tube was almost abandoned inunediately. A six inch tube was tried, but it appeared to have rail distribution problems also along its circumference. Although it was not tested, it was surmised that a five inch tube would distribute the rails evenly around the package. It was noted with each successive experiment that the flexible metal tape connecting the rails together, accumulated more and more damage in the form of creases and bends in the tape. It should be noted, however, that with a single roll-up and a single roll-out, that the support frame is virtually free of defects along the length of the metal tape. However, any successive coiling and uncoiling of the framework is not recommended. The only way in which re-rolling could be withstood is if the flexible metal tape on the vertical joints was made_ from another non-stretchable cloth-like material, preferably woven, and thus be able to be severely bent and yet be able to return to its original shape. Thus far, materials for this type of design have not been investigated. As it now stands, the framework, if coiled on five inch diameter tube and then carefully packed in a box, can be successfully shipped and uncoiled at the building site.

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Cost Oata

SYSTEM DESIGN DATA SHEET For Scheme No. BHKRA-3

Date: August 25, 1981 Array Designer: Burt Hill Kosar Rittelmann Associates Location of System: Roof Mounted Array Type: Integrated (Direct)

DESCRIPTION

Cost per Replacement Action*

NOCT Efficiency

Array Wiring Efficiency Gross Array/Cell Packing

Efficiency

Minor Upkeep Costs*

Array Size (M2) Panel Size (M2) Module Size (M2) Cells/Module Cells/Branch Circuit

Substring

= = = =

=

COST($) REMARKS

$45.52 Module Replacement

$75.00 Cleaning

55.49 m2 1.294 m2 1.294 m2 120 Cells

30

*Break down this element into individual cost items on separate pricing sheets.

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PRICING SHEET For Scheme No. BHKRA-3

Cost Component: COST PER REPLACEMENT ACTION

Date: August 25, 1981 Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT QUANTITY MAT'L MAT'L ITEM UNIT COST

COST

Set-Up 0. 75 Hrs. Cut Out Module 0.25 Hrs. Remove Module 0.25 Hrs. Prepare Module 0.25 Hrs. Place Module 0.25 Hrs. Sealant 1 Tube $7.00 $7.00 Clean-Up 0. 33 Hrs.

TOTAL TOTAL C0ST/M2

LABOR LABOR UNIT COST COST

$19.92 $14.94 10.99 2.75 19.92 4.98

8.93 2.23 19.92 4.98 10.99 2.00 19.92 6.64

TOTAL INSTALLED REMARKS COST

$14.94 2.75 4.98 2.23 4.98 9.00 6.64

$45.52 $52.93 Per Square

Meter of Module

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PRICING SHEET

Cost Component: MINOR UPKEEP COSTS

Date: August 25, 1981

For Scheme No. BHKRA-3

Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT ITEM

Cleaning

TOTAL TOTAL COST/M2

QUANTITY

1

MAT'L UNIT COST

MAT'L LABOR COST UNIT

COST

LABOR COST

TOTAL INSTALLED COST

$75.00

$75.00 $ 1.36

REMARKS

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COST DATA SHEET For Scheme No. BHKRA-3

Date: August 25, 1981 Array Designer: Burt Hill Kosar Rittelmann Associates Location of System: Roof Mounted Array Type: Integrated (Direct)

COST COMPONENT*

COST($) COST ($/M2)

Wiring $ 133.78 $ 2.41 Array/Panel Support

Device( s) N/A Array Assembly 246.55 4.44 Array Installation 288.84 5.21 Mounting Gaskets N/A Sealants 120.00 2.18 Roof Bracing N/A Flashing 36.22 0.66 Rack Structures N/A Module/Panel Mfg.

Costs (from JPL) 3,910.20 70.47 Special Hardware N/A Other N/A

a. b.

Net Installed Cost $4,735.59 $85.37 Roofing Credit*

528.00 9.59

Total Installed Cost $4,207.59 $75.78

% OF TOTAL COSTS

3.2%

5.9% 6.9%

2.9%

0.9%

93.0%

12.7%

*Break down each cost component into individual cost items on separate pricing sheets.

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PRICING SHEET

Cost Component: WIRING

Date: August 25, 1981

For Scheme No. BHKRA-3

Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT QNTY MAT'L MAT'L ITEM UNIT COST

COST

Wiring Harness-! 6 $16.25 $97.50 Wiring Harness-2 I 7.48 7.48

Ins tall at ion: Harness-I 6 Harness-2 1

TOTAL TOTAL C0ST/M2

LABOR LABOR UNIT COST COST

$2.25 $13.50 2.00 2.00

1.80 10.80 2.50 2.50

TOTAL INSTALLED COST

$111.00 9.48

10.80 2.50

$133.78 $ 2.41

REMARKS

Factory Assembled

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PRICING SHEET For Scheme No. BHKRA-3

Cost Component: ARRAY ASSEMBLY

Date: August 25, 1981 Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT QUANTITY MAT'L MAT'L ITEM UNIT COST

COST

2 X 1-1/2 Wood Rails 14x18-l/2 $0.55/ft. $142.45

2 X 1-1/2 Wood Rails 2xl6' $0.55/ft. 17.60

Metal Tape 328 ft. $0.05/ft. 16.40 Staples 2,260 0.010/

Staple 22.60

Attach Tape 1.67 Hrs. to Rails

Set Rails . 33 Hrs.

Attach Vertical Tape .33 Hrs. Package .167 Hrs.

*See Attached Detailed Materials List

TOTAL TOTAL C0ST/M2

LABOR UNIT COST

2.00

10.80 2.50

$15.00/ Hour 15.00/ Hour 15.00 Hour 15.00 Hour

LABOR TOTAL COST INSTALLED

9.48 $142.45

10.80 2.50

$25.00

15.00

5.00

2.50

17.60 16.40

22.60

25.00

15.00

5.00

2.50

$246.55 $ 4.44

REMARKS

*

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PRICING SHEET For Scheme No. BHKRA-3

Cost Component: ARRAY INSTALLATION

Date: August 25, 1981 Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT QUANTITY MAT'L MAT'L LABOR ITEM UNIT COST UNIT

COST COST

Mounting Hardware 2 $9.96/Hr.

Module Installation 42 $9.96/Hr.

*See Attached for Detailed Breakdown

NOTE: 4 man crew 2 glaziers@ $10.99/Hr. 2 laborers@$ 8.93/Hr.

TOTAL TOTAL C0ST/M2

LABOR TOTAL COST INSTALLED

$109.56 $109.56

179.28 178.28

$288.84 $ 5.21

REMARKS

*

*

w 5 KW PV ARRAY INSTALLATION MANHOURS

TASK GLAZIER GLAZIER LABORER LABORER TOTAL

COORDINATION & SET-UP 1/4 1/4 3/4 3/4 2

ROOF CHECK 1/4 1/4 1/2

SET /fl SIDE RAIL 1/4 1/4 1/2

PREPARE MODULES & FRAME 1/4 1/4 1/2

HOIST #1 BUNDLE & ROLL OUT 1/4 1/4 1/4 1/4 1

SQUARE, TACK, SHIM, NAIL 1/2 1/2 1/2 1/2 2

SET /12 SIDE RAIL 1/4 1/4 1/2

PREPARE 112 BUNDLE 1/4 1/4 1/2

HOIST #2 BUNDLE & ROLL OUT 1/4 1/4 1/4 1/4 1

SQUARE, TACK, SHIM, NAIL 1/2 1/2 1/2 1/2 2

PREPARE FLASHING 1/2 1/2 1

INSTALL FLASHING 1/2 1/2 1

SUBTOTAL 2-3/4 2-3/4 2-3/4 2-3/4 11

INSTALL 1ST ROW 3/4 3/4 3/4 3/4 3

BREAK FOR LUNCH 1/2 1/2 1/2 1/2 2

F1 INSTALL 2ND ROW 1/2 1/2 1/2 1/2 3

INSTALL 3RD ROW 1/2 1/2 1/2 1/2 2

INSTALL 4TH ROW 1/2 1/2 1/2 1/2 2

Ld INSTALL 5TH ROW 1/2 1/2 1/2 1/2 2

INSTALL 6TH ROW 1/2 1/2 1/2 1/2 2

CLEAN UP 1-1/2 -

SUBTOTAL 4-3/4 4-3/4 4-3/4 4-3/4 19

TOTAL 8 8 8 8 32

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PRICING SHEET For Scheme No. BHKRA-3

Cost Component: ARRAY/PANEL SUPPORT DEVICES

Date: August 25, 1981 Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT ITEM

N/A

TOTAL TOTAL C0ST/M2

QUANTITY MAT'L UNIT COST

MAT'L COST

LABOR UNIT COST

LABOR TOTAL REMARKS COST INSTALLED

w

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L:d

PRICING SHEET For Scheme No. BHKRA-3

Cost Component: MOUNTING GASKETS

Date: August 25, 1981 Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT ITEM

N/A

TOTAL TOTAL COST/M2

QUANTITY MAT'L UNIT COST

MAT'L COST

LABOR UNIT COST

LABOR TOTAL REMARKS COST INSTALLED

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PRICING SHEET

Cost Component: SEALANTS

Date: August 25, 1981

For Scheme No. BHKRA-3

Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT QUANTITY MAT'L MAT'L ITEM UNIT COST

COST

Silicon GE 1200 4 Gal. $30/Gal. $120

TOTAL TOTAL C0ST/M2

LABOR LABOR UNIT COST COST

TOTAL INSTALLED

$120.00

$120.00 $ 2.18

REMARKS

Labor included in Module Installation

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PRICING SHEET

Cost Component: ROOF BRACING

Date: August 25, 1981

For Scheme No. BHKRA-3

Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT ITEM

N/A

TOTAL TOTAL COST/M2

QUANTITY MAT'L UNIT COST

MAT'L COST

LABOR UNIT COST

LABOR TOTAL REMARKS COST INSTALLED

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PRICING SHEET For Scheme No. BHKRA-3

Cost Component: FLASHING

Date: August 25, 1981 Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT QUANTITY MAT'L MAT'L ITEM UNIT COST

COST

.024" AL 39.37 ft.2 $0.92/ $36.22 Foot

TOTAL TOTAL COST/M2

LABOR LABOR UNIT COST COST

TOTAL INSTALLED

$36.22

$36.22 . $ .66

REMARKS

Labor for Installation Included in Module Installation

......,

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PRICING SHEET

Cost Component: RACK STRUCTURES

Date: August 25, 1981

For Scheme No. BHKRA-3

Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT ITEM

N/A

TOTAL TOTAL C0ST/M2

QUANTITY MAT'L UNIT COST

MAT'L COST

LABOR UNIT COST

LABOR TOTAL COST INSTALLED

REMARKS

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PRICING SHEET For Scheme No. BHKRA-3

Cost Component: MODULE/PANEL MFG. COSTS (JPL)

Date: August 25, 1981 Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT ITEM

Module

TOTAL TOTAL C0ST/M2

MAT'L COST

LABOR LABOR TOTAL REMARKS UNIT COST INSTALLED

QUANTITY MAT'L UNIT COST COST

42 $93.10 $3,910.20 $3,910.20 $0.70/Wp

$3,910.20 $ 70.47

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PRICING SHEET For Scheme No. BHKRA-3

Cost Component: SPECIAL HARDWARE

Date: August 25, 1981 Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT ITEM

N/A

TOTAL TOTAL C0ST/M2

QUANTITY MAT'L UNIT COST

MAT'L COST

LABOR LABOR UNIT COST

COST

TOTAL INSTALLED

REMARKS

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PRICING SHEET

Cost Component: ROOF CREDITS

Date: August 25, 1981

For Scheme No. BHKRA-3

Array Designer: Burt Hill Kosar Rittelmann Associates

COST/CREDIT ITEM

Plywood ( " thick) --

Felt ( 4f weight)

QUANTITY MAT'L UNIT COST

MAT'L COST

LABOR UNIT COST

LABOR COST

TOTAL REMARKS INSTALLED

Shingles (325# 6 Squares $53/Sq. $318.00 $35/Sq. $120.00 $528.00 weight)

Tile Wood Shakes

Size Type ---w/fire retardant)

TOTAL TOTAL COST/M2

$528.00 $ 9.59

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Materials List

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Nomenclature

Material

Quantity

Shape

Size

Weight

Cost

Part Designation

Part Number

Material Type

Number of Pieces

Cross Section

Dimensions of Section

Wall Thickness

Length of Part

Total Length of Parts

Pounds/C.F.

Pounds/Ft.

Pounds/Part

Total Weight of All Pieces

Dollars/Pound

Dollars/Foot

Dollars/Piece

Total Cost of All Pieces

Horizontal Rails

Wd. HR-1

Wood (Western Red Cedar)

7

Rectangular

1-1/2" x 2" actual

Solid Section

37.33 ft.

261.33 ft.

33.0

.6875

25.58

179.07

$.80

$.55

$14.07

$98.48

Nomenclature

Material

Quantity

Shape

Size

Weight

Cost

Part Designation

Part Number

Material Type

Number of Pieces

Cross Section

Dimensions of Section

Wall Thickness

Length of Part

Pounds/C.F.

Pounds/Ft.

Pounds/Part

Total Weight of All Pieces

Dollars/Pound

Dollars/Foot

Dollars/Piece

Total Cost of All Pieces

Side Rails

Wd. SR-1

Wood (Western Red Cedar)

2

Rectangular

1-1/2" x 2" actual

Solid Section

16 .125 ft.

33.0

.6875

11.09

22 .181!

$.80

$.55

$8.87

$17.74

LJ

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Nomenclature

Material

Quantity

Shape

Size

Weight

Cost

Part Designation

Part Number

Material Type

Number of Pieces

Cross Section

Dimensions of Section

Wall Thickness

Length of Part

Pounds/C.F.

Pounds/Ft.

Pounds/Part

Total Weight of All Pieces

Dollars/Pound

Dollars/Foot

Dollars/Piece

Total Cost of All Pieces

Horizontal Metal Tape

HMT-1

Aluminum

7

Crowned

2" wide with 3/16" crown

35 gauge approx.

37 .33 ft.

.024

.893

6. 254f

$2.29

$.055

$2.05

$14.37

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Nomenclature

Material

Quantity

Shape

Size

Weight

Cost

Part Designation

Part Number

Material Type

Number of Pieces

Cross Section

Dimensions of Section

Wall Thickness

Length of Part

Pounds/C.F.

Pounds/Ft.

Pounds/Part

Total Weight of All Pieces

Dollars/Pound

Dollars/Foot

Dollars/Piece

Total Cost of All Pieces

Vertical Metal Tape (including side rails)

VMT-1

Aluminum

6

Crowned

2" wide with 3/16" crown

35 gauge approx.

16.125 ft.

.024

.387

2. 32241

$2.29

$.055

$.887

$5.32

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Nomenclature

Material

Quantity

Shape

Size

Weight

Cost

Part Designation

Part Number

Material Type

Number of Pieces

Cross Section

Dimensions of Section

Wall Thickness

Length of Part

Pounds/C.F.

Pounds/Ft.

Pounds/Part

Stops

RS-1

Metal

84

Flat 1/4" knife blade

l"

1/4" X .025

1-1/2"

Total Weight of All Pieces 1#

Dollars/Pound

Dollars/Foot

Dollars /Piece

Total Cost of All Pieces

$0.15

$19.20

LJ

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Nomenclature

Material

Quantity

Shape

Size

Weight

Cost

Part Designation

Part Number

Material Type

Number of Pieces

Cross Section

Dimensions of Section

Wall Thickness

Length of Part

Pounds/C.F.

Pounds/Ft.

Pounds/Part

Total Weight of All Pieces

Dollars/Pound

Dollars /Foot

Dollars/Piece

Total Cost of All Pieces

Staples

Steel

2260

$0.10

$22.60

L..J

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Ld

Nomenclature

Material

Quantity

Shape

Size

Weight

Cost

Part Designation

Part Number

Material Type

Number of Pieces

Cross Section

Dimensions of Section

Wall Thickness

Gallons/Ft.

Length of Part

Total Length of Parts

Total Gallons of Parts

Pounds/C.F.

Pounds/Gallon

Pounds/Ft.

Pounds/Part

Total Weight of All Pieces

Dollars/Pound

Dollars /Foot

Dollars/Piece

Total Cost of All Pieces

Silicone Adhesive/Sealant GE Construction Sealant 1200

Joint type 4H

Silicone acetoxy

5

.25 in.2

.0129

37.33 ft.

186.65 ft.

2.4

60

84fo

.10

3.73

18.67

$3.75

$.375

$13.99

$69.99

Nomenclature Part Designation Silicone Adhesive/Sealant GE Construction Sealant 1200

Part Number Joint type 4i2

Material Material Type Silicone acetoxy

Quantity Number of Pieces 1 (array perimeter)

Shape Cross Section

Size Dimensions of Section .125 in.2

Wall Thickness

Gallons/Ft. .0065

Length of Part 106.91 ft.

Total Gallons per Part .695

Weight Pounds/C.F. 60

Pounds/Gallon 84f

Pounds/Ft. .05

Pounds/Part 5.56

Total Weight of All Pieces 5.56

Cost Dollars/Pound $3.75

Dollars/Foot $.187

LJ Dollars/Piece $20.85

Total Cost of All Pieces $20.85

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Nomenclature

Material

Quantity

Shape

Size

Weight

Cost

Part Designation

Part Number

Material Type

Number of Pieces

Cross Section

Dimensions of Section

Wall Thickness

Gallons /Ft.

Length of Part

Total Length of Parts

Total Gallons of Parts

Pounds/C.F.

Pounds/Gallon

Pounds/Ft.

Pounds/Part

Total Weight of All Pieces

Dollars/Pound

Dollars/Foot

Dollars/Piece

Total Cost of All Pieces

Silicone Adhesive/Sealant GE Construction Sealant 1200

Joint type 413

Silicone acetoxy

6

.046 in.2

.0023

16.125 ft.

96.750 ft.

.223

60

Bffo

.018

.297

1. 78

$3.75

$0.69

$1.11

$6.68

Nomenclature

Material

Quantity

Shape

Size

Weight

Cost

Part Designation

Part Number

Material Type

Number of Pieces

Cross Section

Width

Thickness

Length of Part

Total Square Feet

Pounds/C.F.

Pounds/Ft.

Pounds/Part

Total Weight of All Pieces

Dollars/Pound

Dollars/Square Foot

Dollars/Piece

Total Cost of All Pieces

Metal Flashing

Aluminum

1 (array perimeter)

Sheet

4.5 in.

.024 in.

105 ft.

39.37

$.92

$36.22

$36.22

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Nomenclature

Material

Quantity

Shape

Size

Weight

Cost

Part Designation

Part Number

Material Type

Number of Pieces

Cross Section

Dimension

Wall Thickness

Length of Part

Pounds/C.F.

Pounds/Ft.

Pounds/Part

Total Weight of All Pieces

Dollars/Pound

Dollars/Foot

Dollars/Piece

Total Cost of All Pieces

Nails

Steel-coated

200

10 d

IOffo

$1.00

$10.00

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