Install Manual GC Max-Span Ground System Piles, Portrait, Bottom Mount Configuration

Transcription

1 Install Manual GC Max-Span Ground System Piles, Portrait, Bottom Mount Configuration CONTENTS I II III IV V VI VII VIII IX GENERAL SAFETY PRECAUTIONS AND RESPONSIBILITY OF INSTALLER MATERIALS AND TOOLS REQUIRED SYSTEM COMPONENTS INSTALLATION OF SYSTEM SYSTEM OVERVIEW MATERIALS, STORAGE AND WARRANTY SITE SELECTION PREVENTATIVE MAINTENANCE

2 I General Please carefully follow this manual to learn how to correctly install the GameChange Solar Max-Span Ground System. The Max-Span Ground System is engineered and tested to withstand wind and snow loads to specification when installed properly. Failure to precisely follow the install manual and to install the racking system properly may decrease the performance of the installation and will void the warranty. This is the generic manual and it includes all components utilized in all variations of the Max-Span Ground System. Please refer to your particular permit/layout detail sheets and bill of materials for the specific components for your system as some components may not be required. II Safety Precautions and Responsibility of Installer The installer is responsible for the following: Following all instructions in this Install Manual Utilization of only qualified personnel Using only GameChange parts. Using other parts to complete the installation as substitutes may void the warranty. Making sure the ground structure (notably in the case of a capped landfill) can support the loading resulting from the Max-Span Ground System Following all safety procedures as outlined in this Install Manual, both for mechanical and electrical aspects of the solar PV array installation Following all safety instructions that are required by relevant local, regional and national organizations Materials are packaged in optimal manner to protect components. Do not un-package until time of installation. Un-packaging and restacking may cause damage to components. General safety precautions: Plan for safe practice during any installation activity with respect to hazards from tripping, falling, lifting, repetitive stress, and any overhead or electrical hazards. Refer to OSHA safety guidelines. Metal components often have sharp edges. Handle carefully! Wearing gloves is good practice. This document is not prescriptive regarding safety and does not purport to address all the safety concerns that may arise with its use. Contractors should become familiar with all applicable safety, health and regulatory requirements before beginning work. Electrical safety notice The Max-Span Ground System is a mechanical system and contains no live parts. Mechanical installers and electricians should coordinate in order to ensure that all personnel are aware of electrical hazards that may result once panels have been placed on the racking structure. Build rate Estimated mechanical installation rate (racks and panels per day) for an array consisting of commercial-class modules installed with the Max-Span Ground System and assuming a well-equipped five-person crew working 8 hours / day with full task interchangeability: approximately 227 panels and racks per day. 15 men install 1.05 MW per week with 300 watt modules. Field modifications and Work arounds Unauthorized field modification and workarounds of Gamechange components or assemblies may affect GameChange warranty coverage. Provide marked up drawings for Gamechange s review, comment and approval prior to attempting. Installers laying out or installing arrays may encounter undocumented or unexpected obstacles requiring a work around. Since PV arrays are intended to be primarily regular and repeating structures, work arounds should be brought to the attention of GameChange personnel prior to being done. If approved by GameChange, they should be noted on working drawings. Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 2

3 All regional safety requirements shall be followed when installing the Max-Span Ground System. All equipment/tools shall be properly maintained and inspected prior to use. This installation manual is intended for use by professional installers with a working knowledge of construction principles. If the install manual is not followed completely the warranty may be voided and the solar system may not operate optimally. III Materials and Tools Required The following tools are required for the installation of the Max-Span Ground System: String line, 48 inch long level and 30 foot tape measure Anti-seize may be beneficial to prevent galling for bolts used to mount panels, but is not required GameChange rack materials (see below) Wrenches and deep and short sockets and drivers: 7/16 inch (for 1/4-inch hex bolts and nuts), 9/16 (for 3/8), and 1 1/8 (for 3/4) Inclinometer of level with digital degree read out Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 3

4 IV System Components The Max-Span Ground System contains the following parts: (This is the generic manual and it includes all components utilized in all variations of the Max-Span Ground System. Please refer to your particular permit/layout detail sheets and bill of materials for the specific components for your system as some components may not be required.) StickyPile TM Post (GC61) NS Beam (GC62H) Brace for NS Beam (GC64HX) EW Purlins (GC63) Bend Strap (GC871) (if req d) Roll Tie (GC872) (if req d) Roll Strap (GC873) Purlin Angle (GC874) (if req d) Purlin Washer (GC126) Wide Beam Washer (GC125) Associated Hardware for Posts (Piles), Braces, Beams, EW Purlins, and other components: Flange nuts, and hex bolts (or flange bolts); 3/8-16 x 1 inch, and 3/4-10 x 1 1/2 inch: Magnacoat Washers 3/8 and 3/4 inch; Hot dip galvanized, magnacoat or stainless steel Panel Mounting Hardware: Stainless steel: o Hex bolts - 1/4-20 x 3/4 inch long o Flange nuts (1/4-20) o External tooth star washer (5/16 inch) Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 4

5 V Assembly and Installation Instructions Step 1: Placement of the Posts Post Installation 1.0 Measure the footprint of the array according to the installer s design and site plan. 2.0 Find the edges of the array according to provided design. 3.0 Drop a string line on the southern edge. 4.0 Mark Post Locations with locator nails according to array plan starting at south-east corner of array -Make sure define distance between foundations is measured from center of post to center of next post along the ground (not from plan view). Otherwise foundation locations will creep if there is rolling terrain since plan view does not factor in dimensions differences caused by terrain. This could make purlin attachment more difficult. 5.0 Install first Post to the proper height above the ground 5.1 There is an adjustment range given by GameChange for posts with a minimum embedment depth governing on one side and the distance for ground clearance requirement on the other. 5.2 This is typically from 4 to 8 inches. 5.3 It is good to vary embedment depth from minimum to maximum allowed on this range in order to align tops of piles in a flat or relatively smoothly sloping fashion as per the ground being flat or sloping. 6.0 Make sure the two longer sides (approximately 6-inch) face East-West, and the open side faces north North 7.0 Make sure next Posts are installed at specified distances from marked locations: 7.1 East-west +/- 1 inches The racking system allows for +/- 2 inches but this will make more adjustment of purlins necessary and slow down installation. 7.2 North-south +/- 1 inch 8.0 Make sure posts are squared to within +/- 1 degree to the azimuth of the array. 9.0 Tops of the posts are leveled to be at a consistent height or slope depending on the topography of the land (with a tolerance of optimally +/- 1 inch). Note that embedment depth will vary. GameChange provides range of embedment depth to allow for this. Be careful to always meet minimum embedment depth Make sure post is plumb, optimally +/- 1 degree so long as: 10.1 Not more than +/- 1 1/2 inches on east to west direction at top of post (from the proper post location marked on ground). The racking system allows for +/- 2 1/2 inches but this will make more adjustment of purlins necessary and slow down installation) 10.2 Not more than +/- 1 inch north to south direction at top of post (from the proper post location marked on ground) Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 5

6 V Assembly and Installation Instructions Step 1: Placement of the Posts Refusal Instructions Inform Game Change immediately if refusal is encountered when driving posts. Refusal is defined as a blow count of 10 or more per inch (120 blows per foot). Refusal of posts shall be addressed as follows: Option 1 Use post at shallower embedment depth a) Based on the embedment of the post at time of refusal and the location of the post relative to the array, GameChange engineering staff may determine it to be acceptable to leave the post at the shallower embedment depth. If instructed by GameChange engineering staff, cut the top of the post to the appropriate height and field drill bolt holes for connection to the beams per post drawings. b) Pull testing may be required to confirm the post at the shallower depth has sufficient resistance to the design uplift and lateral forces. Pull test procedures, including test loads, will be provided by GameChange engineering staff. Option 2 Install post in Aggregate Base Course a) Pull Post out using a crane attached to the topmost slots (or equivalent method) b) Drill hole for Post using a 10 drill to the depth prescribed for Post embedment depth within tolerances. c) Fill hole with aggregate base course. Depending on site conditions, this method may not be applicable, or compaction of the aggregate fill may be required. Consult GameChange engineering staff for more information. d) Drive post at original location, through aggregate, in accordance with typical post installation instructions above. Option 3 Install shorter post in concrete pier a) Pull Post out using a crane attached to the topmost slots (or equivalent method) b) Drill hole for Post using a 12 drill to the depth prescribed for Post embedment depth within tolerances. c) Insert Post into drilled hole and hold plumb. Temporary wooden bracing supports may be used for this. d) Fill with 4,000 psi concrete, in consultation with GameChange to amount of concrete and method of installation. Installing Posts using drill and concrete pouring method to ensure proper Post top alignment: Attach tape to the drill bit (for pre-drilling holes for pile holes to be filled in with concrete) so that the distance from the tape to the bottom of the drill bit is the same as the height of the post. Set a stake at each end of a row line. Attach a string (or aircraft cable and use come-alongs to keep taught) from one stake to the other, and make sure it is at the proper post height above the ground. Dill holes vertically and plumb until bottom of the tape is level with the string. Remove drill and place post in hole. This will align every post to a consistent slope Embedment depth will vary, make sure minimum embedment depth meets GameChange requirements. Please consult with GameChange for more detail. Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 6

7 Deformation at the top of the piles rarely occurs, and typically only when piles are driven into rock, and is minor and easily remedied. Deformation could cause problems for the installation of the NS Beam. If any deformation at the top of the piles occurs during installation: a) If mushrooming is locally isolated above any slots or features and within 1/8 inch of the original drawing dimension (4 15/16 ), use a hammer (or equivalent equipment) to reshape the top end of the Post back to within 1/16 inch of the original drawing dimension. b) If piles are deformed more than 1/8 inch then consult with GameChange regarding re-use. If there is any cracking of galvanized coating on piles make sure to wire brush then paint area with zinc rich paint. Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 7

8 V Assembly and Installation Instructions Step 2: Beam/Brace Assembly 1.0 Place NS Beam on top of Post such that longer part is to South, aligning the 3/4-inch mounting hole with 3/4-inch width slot on top of Post. 2.0 Attach NS Beam to Post using 2.1 3/4-inch bolts 2.2 3/4-inch washers (under bolt heads, on NS Beam side) 2.3 3/4-inch serrated flange nuts (inside Post) 2.4 3/4-inch washers (under serrated flange nuts, inside Post) 2.5 Leave hand tight to allow for adjustment in later steps 3.0 Align 3/4-inch hole on Brace to 3/4-inch width slot in the middle of the Post Attach Brace to Post using 3.1 3/4-inch bolts 3.2 3/4-inch washers (under bolt head, on Post side) 3.3 3/4-inch serrated flange nuts 3.4 3/4-inch washers (under serrated flange nuts, inside Brace) 3.5 Leave hand tight to allow for adjustment in later steps Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 8

9 4.0 Align 3/4-inch slots on Brace to 3/4-inch slots on NS Beam. Attach Brace to NS Beam using 4.1 3/4-inch bolts 4.2 3/4-inch washers (under bolt head, on NS Beam side) 4.3 3/4-inch serrated flange nuts 4.4 3/4-inch washers (under serrated flange nuts, inside Brace) 4.5 Leave hand tight to allow for adjustment in later steps Note: Make sure to review assembly print for specific job and attach to hole that results in tilt as required for installation 5.0 Repeat steps for NS Beam and Brace on adjacent Posts. When installing Beams; make sure all Beams are at the tilt as required for the installation. The NS Beams have to be oriented correctly in the North-South direction, aligned properly in the East-West direction, and are to be at a consistent level height or slope. Using a string line will be helpful to do this. Tighten hardware to specifications. Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 9

10 V Assembly and Installation Instructions Step 3: Purlin Assembly 1.0 EW Purlins attach to NS Beams using: 1.1 Two 3/8-inch bolts 1.2 Two serrated flange nuts 1.3 One Purlin Washer (must use Purlin Channel Washers for 16 gauge Purlins) 1.4 One Wide Beam Washer 2.0 EW Purlins should be installed facing uphill or downhill as shown in drawing set for each individual system provided as by GameChange. 3.0 Post distances may vary due to site conditions or Post installation variances, therefore do not install all table purlins first. If you install all table purlins first, you will likely need to go back and take some of these off and reinstall if connector purlins do not reach. It is better to install only a few table purlins ahead and then go across the row using table then connector purlins as you go. 4.0 Attach first EW Purlin at center holes on the southernmost position to the first and second NS Beams using center set of holes for EW Purlin attachment. 4.1 Hardware attachment sequence: Insert 3/8-inch bolt through Purlin Washer nearest to EW Purlin wall, EW Purlin, NS Beam, and Wide Beam Washer. Make sure Purlin Washer is pushed up tight against the wall of the Purlin, this is important Attach 3/8-inch flange nuts below NS Beam Insert 3/8-inch bolt through EW Purlin furthest from EW Purlin wall, NS Beam, and Wide Beam Washer Attach 3/8-inch flange nuts below NS Beam Finger Tight on hardware After Panels mounted and Purlins properly aligned, tighten hardware to specification, using driver to turn bolt head Alternatively bolts may come up and flange nuts be above purlin 4.2 Then, noting the length of the connecting EW purlin, attach the second southernmost EW Purlin to the third and fourth NS Beams. 4.3 For completing EW Purlin installation on tables: Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 10

11 4.3.1 Install the third EW Purlin up the NS Beam Using the tape measure to confirm the table is square(by cross measuring or golden 345 triangle May need to tighten bolts to hold the table square Install the second EW Purlin and the fourth EW Purlin Use a tape measure or t-square to make the second and fourth EW Purlins are square with the first and third. 4.4 Attach connector EW Purlin to between the table EW Purlins. There will be a nominal drop of 1/8 to 1/4 inch from one purlin to the next, which will result in a small corresponding drop from one panel to the next at these junctions. This is normal for connecting systems and is not a shading or functional issue. Try to attach slots at center if possible. This will make for better spaced panel install Hardware attachment sequence: /8-inch bolts (or serrated head bolts), washers (on either side, one under the bolt head and another under the nut) and serrated flange nuts Alternatively bolt direction may be reversed. Connector EW Purlin Table EW Purlin Picture of table / connecting EW Purlin system installed: Connecting purlins allow for articulation to handle east-west slopes of up to 8% 4.5 Repeat for all table EW Purlins and connecting EW Purlins 4.6 Make sure to attach the alternating table EW Purlins and connecting EW Purlins starting at one end of row and continue to the other end of the row. 4.7 Do not attach table EW Purlins at several points along the row in isolated table format or you may not be able to utilities all of the EW adjustment features provides as easily as if you start on one end and work your way across. Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 11

12 V Assembly and Installation Instructions Step 4: Additional Support Attachments Attaching the Bend Strap 1.0 Bend Straps shall be installed on the underside of the EW Purlins approximately midway between two adjacent Beams. Use 3/8-16 hex bolts and serrated flange nuts. Torque to specification. Attaching the Roll Ties 2.0 Roll Ties shall be installed on the EW Purlins approximately midway between two adjacent Beams (one on either side of the Bend Strap). Assembly drawing will identify where the Roll Ties are to be installed. One Roll Tie will be installed from the top of the southern Purlin web to the bottom of the northern Purlin leg. The other Roll Tie will be installed from the top of the northern Purlin web to the bottom of the southern Purlin leg. Use 3/8-16 hex bolts and serrated flange nuts. The Roll Ties must be taut, this is very important. Torque to specification. Attaching the Roll Straps 3.0 Roll Straps shall be installed at both ends of first and third EW Purlins to the Beams. Use 3/8-16 hex bolts and serrated flange nuts. The Roll Straps must be taut, this is very important. Torque to specification. Bolts through purlin may be installed in either direction with flange nut on either side, however bolts through beam must have head above beam and Flange nut under Beam. Torque to specification. Attaching the Purlin Angle 4.0 Purlin Angles (if required) shall be installed on the underside of the EW Purlins at the holes next to the NS Beams on the upper EW Purlins, holes near the center of the lowest EW Purlin, and the respective holes that line up for the 2 nd and 3 rd Purlin. Use 3/8-16 hex bolts and serrated flange nuts. Torque to specification. Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 12

13 Roll Strap (GC873) Roll Ties, Bend Strap, and Roll Straps installed: Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 13

14 V Assembly and Installation Instructions Step 5: Module Attachment Panel Mounting Hardware: Stainless steel: o Hex bolts - 1/4-20 x 3/4 inch long o Flange nuts (1/4-20) o External tooth star washer 1.0 Attaching first panel to EW Purlin through mounting holes in EW Purlins nearest to NS Beam: 1.1 Place star washer at one location per panel inside panel frame. 1.2 Insert hex bolt through the EW Purlin, through the mounting hole in the back of the panel, then through the star washer. 1.3 Attach with a flange nut on end of bolt inside panel frame over star washer. 1.4 Tighten bolt to specification. 1.5 Repeat 1.1 through 1.4 for three more bolts for each panel without using star washer. Bottom mount method: Portrait configuration: Alternate Panel Mounting Method: If panel mounting hole diameter or slot width is 0.28 or less, the orientation of the bolt and nut can be flipped such that the stack-up order from top to bottom is: hex bolt head, star washer, panel frame mounting hole, EW Purlin mounting hole, and flange nut. 2.0 Repeat for all panels. 3.0 For bottom mount attachment of panels GameChange typically provides slotted panel mounting holes to enable panel adjustment in case purlins are not perfectly aligned due to rolling or otherwise uneven ground situations. 4.0 It is the customer s responsibility to make sure to follow panel spacing guidelines if any are given by panel vendor in their specification sheet or elsewhere, otherwise panel warranty could be voided. In all cases make sure panel spacing is the greater of 1/8 inch or the minimum called out by the panel vendor. This will allow for thermal expansion of panels. GameChange systems typically enable ¼ inch panel spacing if aligned properly. 4.1 Spacing between panels can be set by placing a temporary spacer such as bolt shaft or plywood of same thickness as required for panel spacing between panels while they are being installed. This spacer should be removed after panel installation is complete. Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 14

15 V Assembly and Installation Instructions Step 6: Wire Management It is the installers responsibility to install wiring properly. Care should be taken fasten wire firmly in place to prevent movement or chaffing against metal parts over time. Wires should be checked on a routine basis to make sure they remain firmly attached and in place. IV Assembly and Installation Instructions Step 7: Grounding The modules and EW Purlins are all bonded together across the entire row, East and West. To achieve grounding of the system, GameChange recommends installing Cooper, Burndy, or Eaton UL approved grounding lug(s) with 1/4-inch bolts as in accordance with NEC Article 690 to the Post below the last EW Purlin which has panels attached to it which are to be bonded, using 8 gauge copper wire. The Purlin to Purlin bonded connection is rated for up to 25 amps. Therefore, conductors with expected currents greater than 25 amps may not be installed on the racking system without installing additional grounding measures. The entire system needs to be grounded from a single point to an appropriate grounding source. **Please confirm with an electrician, as this is their responsibility** In case of a configuration where there is a break in the array, UL 2703 listed jumpers (e.g., Burndy WILEYBRAID) may be used to bond one segment of the array to the next (only one jumper in between two tables). Install jumpers via unused or field-drilled holes on the Purlin, Beam, or Post, and using UL 2703 approved attachment methods. VI System Overview The Max-Span Ground System is a simple, affordable, easily installed ground-based solar mounting system. Components are made from galvanized and stainless steel. Max-Span Ground System may be installed on solar arrays of up to 200,000 solar panels each (approximately 50 MW). Maximum panel size for the system shall be 45 x 82 inches. Slopes up to 10% are allowable under all normal conditions for continuous systems, and up to 30% for table systems only in consultation with GameChange personnel. VII Materials, Storage and Warranty All materials are made from non-corrosive materials, galvanized, magni coated or stainless steel, with a product warranty of twenty (20) years. Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 15

16 Make sure to install system within several days of receipt of components. Storage of components in a damp or wet environment can lead to white rust on galvanized parts as well as other damage on other protective coatings which can lead to accelerated corrosion of components, and void the warranty. Galvanization is especially prone to white rust when components are still bundled because the zinc coating requires airflow over its surface to establish its protective patina, otherwise water can cause corrosion of the zinc and it has no protection against it in enclosed spaces, such as those between parts that are bundled. VIII Site Selection Proper preparation of surface must be ensured for a well-performing system to be installed. For continuous racking without breaks, ground must be at an east-west slope not to exceed 5 percent to minimize east /west shading from panel to panel. Grading of the ground on the installation area is the responsibility of the customer and should be completed properly to enable the slope tolerance for the Max-Span Ground System. General guidelines include: Choose a clear area free of shading Suggested ten (10) foot border surrounding array IX Preventative Maintenance Proper preventative maintenance must be conducted or warranty may be voided. After installation of the Max-Span Ground System, installer must annually monitor for any surface rust that may occur over time due to scraping of the components or for any other reason. While the extensive galvanizing protection should minimize any such rusting, it is essential that preventative maintenance be performed annually to include: Identifying any rust areas Wire brush the rust area to remove all rust Coat the area with 70%+ zinc rich or equivalent field life paint This step is not required if rust is limited to edges which were cut during fabrication After extreme wind turbulence (in excess of 80% of design wind speed), and on an annual basis, an inspection must be done for mechanical movement (which could also be due to any reason including thermal expansion and contraction). Any mechanical movement must be rectified. Torque settings must be checked for all hardware. All Clips shall be checked to make sure there is no gap between the side of the Clips and modules. It is estimated that two qualified persons should be able to properly inspect and maintain racking for approximately 1,000 panels per day. Rev GC Max-Span TM - Install Manual Piles, Portrait, Bottom Mount Configuration 16