Let's break down your PV system refresh plan

1) Identifying the Racking System:
Visual Clues

While a single picture from that angle makes positive identification difficult, there are a few things to look for to narrow down the possibilities:

Clamping Style

Notice how the panels are clamped. Are they clamped on the long sides (most common) or the short sides? What kind of clamp is used - a standard mid-clamp and end-clamp, or some proprietary design?

Rail Shape

Is the rail a simple rectangular extrusion, or does it have a more complex profile with channels or grooves?

Grounding

Does the system use grounding lugs, or is it a grounded system with an integrated grounding mechanism through the rails and clamps?

Manufacturer Markings

Look closely at the rails, clamps, and mounting feet. Sometimes, the manufacturer's name or logo is stamped or embossed on the components. Even a part number could help greatly.

Research & Comparison

Search online for solar panel racking systems. Look at the images and documentation of major manufacturers like: Unirac IronRidge SnapNrack EcoFasten Solar DPW Solar (Direct Power and Water)

Installer Records

If you have any original installation documents (permit applications, invoices, etc.), they might identify the racking manufacturer.

2) Reusing the Racking System: Feasibility & Considerations

You are correct: module sizes have evolved since 2012. Finding a perfect "drop-in" replacement in that specific height is unlikely. Here's a detailed look at the feasibility of reusing the racking: Is it worthwhile to reuse the rails? Possibly. Here's the thought process: Condition

First,

thoroughly inspect the entire racking system. Look for: Corrosion

Check for pitting, rust, or white oxidation (aluminum corrosion), especially at joints and where dissimilar metals meet (e.g., steel screws in aluminum rails).

Damage

Inspect for bending, cracks, or any signs of physical stress.

Loose Fasteners

Check the torque of all bolts and screws. Are any stripped or corroded?

Grounding Integrity

If the system is grounded through the racking, ensure all grounding connections are clean and secure.

Code Compliance

Solar codes have changed since 2012. If you're increasing the power or changing the modules, it is very likely that your local inspection authority will want to see an updated structural analysis on the array.

Cost Comparison



Get quotes for a completely new racking system and for just new modules with potentially modified or reused racking. Compare the total costs, including labor. Consider not just the upfront cost, but also the long-term reliability and potential maintenance costs of the old racking. Accommodating Different Module Sizes



Option 1: Overhanging Modules



Pros

Potentially simplest if the overhang is minimal.

Cons



Aesthetics

The overhang might look unusual and could be a concern for some.

Wind Load

Overhangs increase the surface area exposed to wind. You'll definitely need to check the racking's wind load capacity with the overhang. Consult with a structural engineer or the racking manufacturer (if you can identify them) to ensure it can handle the load.

Snow Load

Similar to wind, overhangs can increase snow load.

Edge Effects

Exposed module edges are more vulnerable to damage.

Option 2: Adding an Offset/Spacer



Pros

Maintains a more flush and potentially more aesthetically pleasing appearance.

Cons



Engineering/Fabrication

You'll need to design and fabricate a safe, structurally sound, and weather-resistant spacer. This might require custom metalwork.

Cost

Fabrication and installation could be expensive.

Compatibility

The offset needs to be compatible with the racking, the modules, and local code.

Top Mounting Modules Directly

Some racking systems can accommodate mounting panels on top of the rails with the correct hardware. You'd need to see if that is a possibility in your case.

Module Placement Considerations



Airflow

Ensure there is adequate airflow behind the modules to prevent overheating. Overheating reduces efficiency and can shorten the lifespan of the modules.

Shading

Carefully consider any potential shading from trees, buildings, or other obstructions. Larger panels might be more susceptible to shading.

Recommendations


Identify the Racking

Dedicate time to identifying the racking system manufacturer and model. This is crucial for determining its load capacity, compatibility, and available accessories.2.

Detailed Inspection

Perform a thorough inspection of the existing racking system, paying close attention to corrosion, damage, and fastener torque.3.

Professional Consultation

Consult with a qualified solar installer or structural engineer. They can: Assess the condition of the racking. Determine if it meets current code requirements. Evaluate the feasibility of adapting the racking to accommodate new modules. Perform a structural analysis to ensure the racking can handle the wind and snow loads in your area with the proposed module configuration.4.

Cost Analysis

Get detailed quotes for both reusing the racking (with modifications if necessary) and installing a completely new system.5.

Warranty Considerations

Consider that reusing the racking may affect the warranty of the new panels or any potential workmanship warranty on the installation.6.

Safety: Working on a roof can be dangerous. If you are not experienced, hire a professional.In summary, reusing the racking might* be feasible, but it depends heavily on its condition, code compliance, and the feasibility of adapting it to new module sizes. A thorough inspection and consultation with professionals are essential before making a decision. Don't make the decision solely on the basis of cost savings - factor in the long term risks. Flag for review