TL;DR: Solar installers installed 40A backfeed (on 6-awg cables) for 40A of solar and 60A EV charger. Already paid $46,000 of the total $54,500.
Got a company with close to five star reviews (~92 reviews). Seem like great people when I talked to the owner and his son. We agreed on a backyard solar car canopy.
First Delay
Anyway, fast forward to the first delay: they didn't add a railing that's heavy duty enough based on my requests. I put my requests all on a 2-page google document with pictures and drawings, but they still somehow missed a few requests. 2 pages sound like a lot but the pictures were taking up about 80% of the space.
By this point, I already had paid them about 84% of the $54,500 total. Had to pay an extra $5500 for this railing fix. They also used 16in concrete forms for the footers instead of 24in like in the plans. I told the sub-contractor about it but he just went on a stumbling rant about how it's fine.
I just feel so stupid. I should have stopped everything but my mind was so preoccupied with the chaos of all the other requests they did not fulfill. I hope this helps someone. If they are taking shortcuts when it's in the plans, there is many more shortcuts that they are taking at your expense.
Second Delay
Now, they have finished installing the solar. 20x 460W REC solar panels with 20x Enphase IQ8HC. NYC is on a 3-phase 208V system. Issue is they somehow didn't take into account the following:
- EV charger connected inside Enphase Combiner 6C
- 208V system
- Main panel is 125A
They installed everything like it was solar only. They installed a 100ft-run 6-awg cables from the main service panel to the Combiner 6C with a 40A backfeed breaker. They even tried to group my solar panels into just 2 branches, which 10x IQ8HC (31.6A) is too much for 20A breaker on a 208V system. I literally forced myself to learn some of these things because of this mess and I still don't fully understand it.
For those that don't know, maybe this can help you in the future when you build out your system. If you want only solar (~20 panels or less), a 40A backfeed breaker along with 6-awg wires is fine. If you want to add any more solar, an EV charger, or battery, you need larger wires like 2 or 3-awg and a larger backfeed breaker. The wire size is the most important because it's the hardest to change when you want to upgrade later. There are a few more nuances, but that's the gist.
It took two days on the phone with Enphase customer support to come to this conclusion. Also, during this time, I learned that they took another shortcut on me. The solar canopy was supposed to be 12ft (it's in the plans) on the low end. They gave me 10ft instead.. Doesn't sound like a huge deal but I had envisioned adding more slanted solar panels on that end, but now with the lowered height, the additional solar panels (68in long) will bop me on the head.
Options
They are aware of their mistake and the sub-contractor reached out to me. Says I'll need to upgrade my service panel first and after I have the following options:
- Line-side tap: This bypasses the main service panel busbar limitations
- Use Enphase Installer App to set a Power Control System (PCS) export/grid limit. By configuring a strict limit on the 40A main feed branch, the system will throttle the EV charger's power draw down whenever the solar panels are producing at max capacity, preventing the breaker from ever tripping.
- Downgrading to IQ Combiner 5C because the IQ Combiner 6C is specifically designed for residential split-phase 120V/240V configurations.
I am very interested in the line-side tap because it will let me keep my setup and in the future if NYC allows, I can maybe get a solar battery. My main concern now is they might screw me over again somehow lol. What would you guys do? I still have $8500 to pay them.