Rocky Broad Solar
Ultimate DIY Guide

Harnessing the sun from the shadows of Appalachia.

🏔 Rocky Broad River · Western NC

⚡ BEGINNER FRIENDLY 🔋 BATTERY STORAGE 🏠 WHOLE-HOME BACKUP 📋 NEC CODE TIPS 🛠️ DIY FRIENDLY

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📋 What's in this guide

1 Solar Basics 2 System Types 3 Budget Packages 4 Wiring Diagrams 5 System Recommender 6 NEC Code Tips 7 Installation Steps 8 Video Tutorials
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Safety First — Read This

Electricity can seriously injure or kill you. This guide is for educational purposes only. All electrical work should be performed by or under the supervision of a licensed electrician. Always follow local codes and pull the required permits.

Solar 101: How It All Works

Before spending a dime, understand these core concepts. A solar + storage system is really just a few components working together.

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Solar Panels (PV)

Photovoltaic panels convert sunlight into DC electricity. More panels = more power. Roof mount or ground mount — both work. All-black panels look best on a visible roof. Skip bifacial panels unless you have a ground mount or tilt rack where the back of the panel gets sun exposure.

Inverter

The brain of the system. Converts DC solar power to AC power your home uses. A hybrid inverter also manages grid, battery, and solar sources simultaneously — acting as an intersection of power sources rather than a drawbridge.

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Battery Bank

Stores excess solar energy for use at night or during outages. Lithium Iron Phosphate (LFP) is the gold standard — safe, long-lasting, no maintenance. More batteries = better system performance. Go big or go home.

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Grid Connection

Hybrid systems stay connected to the grid as a backup source and can export excess power for credits (net metering) on your utility bill. This is what separates a hybrid inverter from an off-grid inverter.

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CT Clamps

Current transformers measure your home's energy use in real time. They let your inverter intelligently manage power flow — critical for bill savings. On the EG4 GridBoss, CT clamps are built right in.

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Rapid Shutdown (RSD)

Required by NEC 690.12 for roof-mounted systems on habitable buildings. Shuts down panel-level DC voltage within 30 seconds so firefighters aren't electrocuted on the roof during an emergency.

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The 80/20 Rule of Energy Bills

Your HVAC, electric water heater, and EV charger likely account for 80–90% of your electric bill. A system that can control those loads will save you the most money. Portable power stations generally cannot do this — hybrid inverters can, especially when paired with a GridBoss's smart circuit ports.

Which System Type Is Right for You?

There are four main paths. Choose based on your goals, home size, and budget.

✅ Easiest
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Portable Power Station

Plug-and-play. Great for camping, RVs, or powering a few devices during outages. Not suitable for reducing your utility bill — no CT clamps, no grid interaction, limited PV input. Top picks: Anker SOLIX F3800, Anker SOLIX F2600, Anker SOLIX F1500, Jackery Explorer 5000 Plus, Jackery Explorer 3000 Pro, Bluetti, OUPES Guardian 6000.

🔧 Partial Backup

Off-Grid Inverter (Partial Home)

An off-grid inverter like the EG4 12000XP V2 can be connected to the utility grid as a secondary power source — but there's a key difference from hybrid: it's either grid or solar/battery, never both at the same time. Great for backing up a dedicated 100A sub-panel of critical loads. Supports one smart port for load shedding or integrating an existing solar system, also known as “AC coupling.”

⭐ Most Popular
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Hybrid Inverter System

The best of all worlds — uses solar, batteries, and the grid simultaneously. Can offset your bill, export power for net metering credits, and provide whole-home backup. Requires permits in most areas. Recommended for most homeowners.

🏕️ Off-Grid
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Off-Grid System (No Utility)

Fully self-sufficient — no utility connection needed. Off-grid inverters can accept the grid as a secondary backup source, but cannot use both grid and solar/battery power simultaneously like a hybrid can. Cannot export back to the grid. Best for cabins, remote land, or grid-independent living. Shorter warranties (5 yr) and generally fewer certifications for inspections.

Top picks: EG4 12000XP V2 (whole-home, 28kW PV, 15kW output) · EG4 6000XP (budget option, 10kW PV, 6kW output, 120/240V)

Feature Portable Partial (Off-Grid Inv.) Hybrid ⭐ Off-Grid
Reduces utility bill
Whole-home backup ❌ (partial) ⚠️ up to 100A panel
Grid + Solar simultaneously ❌ (one or other) ❌ (one or other)
Grid export / net metering
Permit required? Usually No Often Yes Usually Yes Sometimes
Inverter warranty 2–5 yr 5 yr 10–15 yr 5 yr

Complete System Packages by Budget

These bundles are designed for the average American home. You can always expand later — EG4 systems are modular. All products available through Signature Solar or Current Connected.

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Electrical Diagrams

Visual reference for how a hybrid solar + storage system connects together. Always follow NEC code and local AHJ requirements.

Hybrid System — Power Flow Overview

CT clamps are built into the EG4 GridBoss. Smart circuit ports directly control HVAC, water heater, and EV charger — shedding them automatically during outages or programmed time windows.

☀️ Solar Panels DC Output DC Strings Tigo RSD Roof MLPEs EG4 FlexBoss Hybrid Inverter MPPT • BMS AC Out ↓↑ AC In 120/240V Split Phase EG4 Battery WallMount LFP 14.3–16 kWh/unit DC Bus Portable Gen. + Chargeverter → Battery GridBoss MID CT Clamps Built-In Smart Ports ×3 SP1 → 🌡️ HVAC SP2 → 🚿 Water Heater SP3 → 🚗 EV Charger Near utility meter Grid interconnect point Whole-home gen. input Smart Port Loads 🌡️ HVAC 🚿 Water Heater 🚗 EV Charger Utility Grid 120/240V AC service Whole-Home Gen. Wired directly to GridBoss Backup Loads Panel 💡 Lights + Outlets 🔌 Critical circuits Non-Backup Panel Optional · Grid-only loads Pool · Spare circuits Legend: DC Power AC (backed up) Grid connection Smart port output Optional generator Smart Ports: Shed HVAC, water heater & EV charger automatically during outages or on-peak hours to protect battery reserve Generators: Portable gen. feeds battery bank via Chargeverter (DC path) · Whole-home standby gen. wires directly into GridBoss (AC path)

Solar Panel Stringing — Series vs Parallel

Series String Voltage adds up · Same amps Panel 1 40V · 10A Panel 2 40V · 10A Panel 3 40V · 10A 120V · 10A ✅ Higher voltage → less wire loss Stay within inverter max VOC! Parallel String Amps add up · Same voltage Panel 1 40V · 10A Panel 2 40V · 10A Panel 3 40V · 10A 40V · 30A ✅ Current increases → more power Stay within inverter max string current! ⚡ Critical Rule: NEVER exceed inverter max VOC. Cold climates can push voltage up to 15% higher. Always use a stringing calculator with your zip code!

🛠️ Personalized System Recommender

Answer a few questions and we'll recommend the right inverter, battery count, panel count, and products — with links to buy.

⚡ Tell Us About Your Setup

Fill out the form below for a tailored equipment recommendation.

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🎯 Your Personalized Recommendation

📺 Watch Related Videos

These Rocky Broad Solar videos are most relevant for your setup:

Rocky Broad Solar LLC — Full YouTube ChannelComplete installation walkthroughs, tips & tricks

📋 NEC Code Tips for Passing Inspection

These are the most commonly cited NEC violations on DIY solar installs. Know these before your inspector shows up.

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Always Call Your Local AHJ First

Your Authority Having Jurisdiction (local building/electrical department) has the final say. Requirements vary widely by jurisdiction — always contact them before starting work or spending money on equipment.

Working Clearances — Space in front of equipment
NEC 110.26

Every piece of serviceable electrical equipment needs clear working space in front of it. The inspector will measure this — don't skip it.

  • Height: 6.5 feet tall (from floor up)
  • Width: 30 inches wide, or the width of the equipment (whichever is greater)
  • Depth: 3 feet deep in front of the equipment face
  • Doors: All equipment doors must open at least 90°

Also check NEC 110.26(e) for "dedicated space" requirements above equipment — typically the space directly above a panelboard must be kept clear of foreign systems (pipes, ducts, etc.).

🏠 Stacked FlexBoss + 2 WallMount Batteries: You need roughly 84.5" tall × 56.27" wide of space. Plan your garage or utility room layout before purchasing mounting hardware.
Rapid Shutdown — Required for roof-mounted systems
NEC 690.12

If your panels are on a habitable structure, every module must be able to shut down to a safe voltage (≤30V) within 30 seconds of triggering. This protects firefighters.

  • Tigo TS4-A-F — RSD only (1 per panel), same orientation required, cheapest option
  • Tigo TS4-A-2F — RSD only (1 per 2 panels), same orientation required
  • Tigo TS4-A-O — RSD + monitoring + optimization (best overall for shading or mixed orientations)
  • All options need a Tigo Cloud Connect Advanced (CCA) data logger kit
  • An external RSD switch must be located near your utility meter
  • You'll also need a roll of 18 AWG 4C Shielded VNTC Tray Cable to run between the CCA, TAP, and RSD switch
💡 Important: EG4 inverters have built-in RSD functionality but are NOT compliant out of the box. You MUST add Tigo MLPEs for roof-mounted systems to be code compliant.
DC Wiring in Attics — Conduit & depth requirements
NEC 690.31

DC wiring from your panels to the inverter requires metallic conduit once it enters a habitable building (attic counts).

  • Conduit must be at least 10" below roof decking if run in the attic
  • Outside only: weather-tight conduit (PVC, EMT) is acceptable
  • Inside: use Flexible Metallic Conduit (FMC) or Liquid-Tight FMC for exterior
  • 2 strings + Tigo comms wire = ¾" conduit minimum
  • 3 strings + Tigo comms wire = 1" conduit recommended
💡 Beginner Tip: 10/2 Armored Metal Clad (MC) cable is pre-filled — no pulling wire through conduit. Great for solo DIYers. One cable per string.
Fire Access Pathways & Battery Fire Codes
IFC / NEC 706 / UL9540A

Fire codes for solar and battery storage systems are some of the most jurisdiction-specific requirements you'll encounter. Requirements vary dramatically by local AHJ and adopted fire code edition.

  • Roof fire access pathways: Many AHJs require clear pathways between 18" and 3' wide on the roof for firefighter access. This affects how you lay out your panel array — verify before designing your layout.
  • Battery spacing from openings: Some AHJs require a minimum 3' clearance between batteries and any window or exterior door, and/or between individual battery units.
  • UL9540A listing: Some AHJs require the entire Energy Storage System (ESS) to be listed under UL9540A (or UL9540). EG4 hybrid inverters and EMP-hardened products carry these certifications — budget non-listed batteries do not and may never be permittable.
  • Fire barriers: Some AHJs require drywall or other fire-rated barriers between the battery installation area and living spaces.
  • Smoke and heat detectors: Some AHJs require hardwired smoke and/or heat detectors in the battery installation room.
⚠️ Bottom Line: Contact your local fire marshal or building department before purchasing equipment or designing your layout. A $500 call with a local solar contractor or permit expediter can save you thousands in failed inspections and redesigns.
Battery Location — Habitable space restrictions
NEC 706 / IBC

Batteries cannot be installed in habitable spaces. Unfinished basements, utility rooms, and garages are the typical approved locations.

  • Garage installs: Many inspectors require bollards or mounting 3'+ off the floor to protect from vehicle impact
  • Batteries with internal heaters (EG4 WallMount, PowerPro) are required in locations that drop below freezing
  • An indoor location protects from heat, cold, theft, and vandalism — always prefer indoor when possible
💡 Pro Tip: Verify all battery location requirements with your local AHJ before purchasing mounting hardware. Requirements can vary even within the same county depending on the inspector.
Labeling Requirements — Critical for passing inspection
NEC 690.53 / 690.54

Inspectors will fail an installation for missing labels. This is the most common reason for a failed inspection — and the easiest to fix in advance.

  • AC disconnect must be labeled with voltage, current, and source
  • DC conduit must be labeled "PHOTOVOLTAIC POWER SOURCE"
  • Main panel must have "WARNING — SOLAR ELECTRIC SYSTEM CONNECTED" label
  • RSD switch must be labeled and located near utility meter
  • Combiner boxes must display max voltage/current ratings
🛒 Buy This: A Photovoltaic Solar System Installer Label Kit has every required label in one pack for under $25. It's the cheapest insurance against a failed inspection.
Grounding & Bonding — Don't skip this
NEC 690.47 / 250

Improper grounding is one of the most dangerous and most commonly cited violations. Your entire system must be properly grounded and bonded.

  • All panel frames must be bonded together with bare copper wire
  • Racking system must be grounded back to the inverter
  • DC equipment grounding conductor (EGC) must run with DC wiring
  • The GridBoss has specific grounding and bonding requirements — watch the Rocky Broad Solar GridBoss wiring video before connecting
💡 Use a Ground Bar Kit: The Siemens EC3GB212 Ground Bar Kit with 21 terminal positions makes clean rooftop grounding much easier and more professional-looking.

Installation Roadmap

A step-by-step overview of how a hybrid system installation flows from start to finish.

1

Design Your System

Calculate your energy needs, choose your equipment (inverter → batteries → panels in that order), and run a solar stringing calculator with your zip code and panel VOC data. A professional system design typically costs around $250 and can save you far more in mistakes. Good designers also produce permit-ready single-line drawings.

2

Structural Engineering Stamp

Most AHJs require a licensed structural engineer to review and stamp your roof racking plans before issuing a permit. They verify your roof can handle the added load of solar panels and racking hardware. Some AHJs also require an Electrical Engineering stamp on the single-line diagram. Structural stamps typically cost $150–$500 depending on your location and system size. Many solar equipment distributors and permit expediting services can connect you with a stamping engineer.

3

Pull Permits & Utility Interconnection

Submit your stamped drawings, single-line electrical diagram, equipment cut sheets, and site plan to your local AHJ. Permit fees typically range $100–$500. Utility interconnection is a separate process — your utility must approve the system before you connect to the grid or export power. Utility requirements vary greatly: some require additional PV system disconnects, a dedicated PV production meter, a battery disconnect, or a whole-system disconnect beyond what the NEC requires. Interconnection application fees also vary widely, from $150 to over $2,000 depending on the utility. Start the interconnection application early — approval can take weeks to months.

4

Mount Panels on Roof or Ground

Install racking, mount panels, make MC4 connections. On standing seam metal roofs use S-5 clamps — no roof penetrations needed. On asphalt shingles use flashed J-boxes. Run DC wiring in appropriate conduit down to inverter location. Install Tigo MLPEs if roof-mounted (required for RSD compliance).

5

Mount Inverter & Batteries

Choose your indoor location with proper working clearances per NEC 110.26. Stack the inverter on top of the batteries using EG4 conduit boxes — this simplifies connections and eliminates custom cable runs. Mount the GridBoss near the utility meter if needed. Verify all fire access and spacing requirements before final positioning.

6

Make All Electrical Connections

Connect battery bank via paralleling cables. Connect AC output to GridBoss or load panel. Wire smart ports for HVAC, water heater, and EV charger. Install CT clamps at main service conductors (or use the GridBoss's built-in CTs). Plugging in the solar panels is the very last step — make sure all DC disconnects are in the OFF position before making any panel connections. This protects you and your equipment from live DC voltage during the rest of the installation.

7

Label Everything

Apply all required NEC labels before the inspector arrives. Label all conduit runs, disconnects, breakers, the main panel, and the RSD switch. Missing labels are the #1 cause of failed solar inspections — don't skip this step.

8

Commission & Program the System

Power up carefully following the manufacturer's sequence. Program inverter settings for your utility connection, battery SOC limits, smart port load-shed schedules, and time-of-use optimization. Monitor via app for the first week to confirm everything is performing as expected.

9

Final Inspection & PTO

The inspector checks working clearances, labeling, grounding/bonding, conduit fill, breaker sizing, RSD compliance, fire access pathways, and equipment specs. After passing, contact your utility to request Permission to Operate (PTO) before exporting power or running the system in grid-tied mode. Operating without PTO can result in your utility disconnecting your service.

Video Tutorials — Watch the Full Series

Rocky Broad Solar's YouTube channel covers every step of installation in detail. These videos are the best companion to this guide.

🎬 Rocky Broad Solar — Full Installation Series

Real DIY installs, no fluff. Watch before you buy anything.

Subscribe to Rocky Broad Solar LLC on YouTubeNew install videos, product reviews, and DIY tips regularly
⚠️ Safety Disclaimer: This guide is for educational purposes only. Electricity can kill you. All electrical work should be performed by a qualified professional. If you are not qualified, please hire a licensed electrician.

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