Empowering Commercial Spaces With Smart Solar Design

Project Overview

A US-based client approached our team with a clear goal: To engineer a complete rooftop solar installation, integrated with their existing building. The scope of their brief demanded precise structural assessments, optimized system layouts, and full regulatory compliance.

The Challenge

Spanning multiple composite-shingle roof sections, the project required optimized array placements and precise structural evaluation to achieve maximum energy yield, without compromising roof integrity. 

Structural Constraints

• The building used a composite shingle roof with 2×6 trusses at 24” O.C. 
• Required 500+ structurally aligned attachments to maintain load limits and preserve roof integrity.

Multi-roof Layout Complexity

• Multiple roof planes with hips, valleys, vents, and skylights. 
• Strict 4ft fire setbacks—affecting layout, stringing, and conductor routing. 

Electrical & Utility Coordination 

The optimized design strategy delivered strong performance outcomes across compliance, cost, and commercial metrics.

• NEC 705.11-compliant line-side interconnection.
• SEL-751 relay and isolation contactor requirement for export control.
• Careful voltage drop and ampacity design for long rooftop conductor runs.

The Solution 

We engineered a comprehensive 236.30 kW DC rooftop solar installation tailored for long-term reliability and seamless integration with the client’s building structure. 

Through detailed shading analysis, load assessment, and electrical coordination, our design team ensured that every component remained efficient under real-world conditions. 

The system was carefully designed to align with all NEC requirements and utility standards, ensuring safe, compliant, and future-ready operation.

Optimized Mounting & Structural Design

• Rail-based system with flashed L-feet, aligned with rafters for uniform load distribution and watertightness.

Software-Driven System Modeling

• HelioScope/Aurora for shading & production modeling.
• AutoCAD for layouts and conduit routing.
• SolarEdge Designer for voltage, string sizing, and optimizer mapping.

High-Efficiency Components

• Jinko 425W modules + SolarEdge P1101 optimizers.
• (4) SolarEdge 50 kW inverters (208V).
• 800A AC combiner panel, fused 800A utility disconnect, CT cabinet.

Grid Integration

• SEL-751 programmed for ≤150 kW export.
• Compliant OCPD, conductor sizing, and voltage drop mitigation.
• Clean coordination of inverters, AC disconnect, combiner, and tap point.

Code & Permitting Execution

• NEC 690/705 compliance, rapid shutdown documentation
• Structural load analysis & point-load breakdown
• Complete riser diagrams, labels, and safety placards for AHJ approval.

The Result 

What we got is a system that generates an estimated 263.9 MWh of clean energy annually, significantly reducing operational energy costs and enhancing sustainability performance overall. Clean energy paired with the confidence of a system designed to last. 

High Performance & Energy Yield

An optimized module layout, strategic shade mitigation, and module-level electronics helped ensure strong annual energy production. The design maximizes system efficiency across multiple roof sections, resulting in consistent and dependable long-term output.

Preserved Roof Integrity

Accurately flashed all penetrations to protect against weather exposure and leaks. We also ensured all attachments were aligned directly with structural members to meet load requirements. This approach helps maintain roof performance and ensures long-term durability.

Full NEC & Utility Compliance

The system met NEC 2020 standards, IFC fire setback rules, and all local utility export requirements. Protective relays and compliant interconnection methods further ensure safe operation, allowing us to guarantee a code-aligned and inspection-ready installation.

Smooth Permitting & On-Time Delivery

We provided a complete engineering package with detailed structural, electrical, and layout documents, accelerating AHJ approvals. Utility reviews were completed with minimal feedback or revisions, moving the project smoothly from design to installation.

Highlights: 

• System Size: 236.30 kW DC
• Annual Production: 263,878 kWh
• Performance Ratio: 82.2%
• Roof Type: Composite shingles, 26,144 sq. ft.
• Solar Access: 98%
• Inverters: (4) SolarEdge 50 kW
• Modules: Jinko 425W N-type
• Interconnection: Line-side tap with SEL-751 export limiting to 150 kW

The Finulent Value 

For EPCs / Installers:

• Field-ready, conflict-free designs that streamline installation.
• Fewer change orders and faster inspection approvals.
• Higher ROI through optimized DC–AC ratios and export-control solutions.

For Building Owners:

• Safe integration with existing roof structures and building systems.
• Reliable long-term energy performance and operational cost savings.
• A future-ready solar asset designed for durability and compliance.

This project came together through a careful coordination between design intent and real-world constraints. Fully engineered projects like these allow us to show our commitment to delivering dependable, high-efficiency solar systems that support long-term energy savings for commercial clients.