Powers Solar Frames, LLC Gator-Clamp Installation and Inspection Manual

Transcription

1 Powers Solar Frames, LLC Gator-Clamp Installation and Inspection Manual Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 1

2 TABLE OF CONTENTS INSTALLATION OVERVIEW PAGE 3 EXAMPLE PROJECT PLANS PAGE 4 SOLAR PANEL ATTACHMENT PAGE 8 BONDING PATH DIAGRAM PAGE 9 PERIODIC INSPECTION AND MAINTENANCE PAGE 9 SPECIFICATIONS PAGE 10 ANNEX 1 - DRAWING SKI PAGE 11 ANNEX 2 - DRAWING GM52 PAGE 12 ANNEX 3 - DRAWING - SSK1 PAGE 13 ANNEX 4 - CONSTRUCTIONAL DATA FORM (CDF) PAGE 14 DRAWINGS OF PARTS AND COMPONENTS OF QUALIFIED SYSTEM PAGE 18 DRAWING - INTERIOR SUPER PURLIN PAGE 19 DRAWING - EXTERIOR SUPER PURLIN PAGE 20 DRAWING - INTERIOR PURLIN L - CLIP PAGE 21 DRAWING - END CAP/CLIP PAGE 22 DRAWING - GATOR CLAMP PAGE 23 REVISION HISTORY PAGE 24 Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 2

3 INSTALLATION OVERVIEW Install solar structure per engineered project plans, whether it be carport, ground mount ballasted system or other. Sample plans are included in this document. This racking system is intended for carport, ground mount and ballasted systems. Typical Assembly steps would be: 1) Drill or dig foundation per as specified on project plan. 2) Set column per detail on project plans. 3) Set rafter/beam on column per project plan and this manual. 4) If purlin clips are required (depending on structure type) and not pre attached from manufacturer, then attach per plans. (Also see Annex 1) 5) Attach Super Purlins per project plan and this manual. (Also see Annex 1) 6) Set Solar Panel in Super Purlins according to instructions in this manual. (Also see Annex 2) 7) Attach Solar Panel to Super Purlin with Gator-Clamp according to instructions in this manual. (Also see Annex 2) 8) Affix UL 2703 label to Super Purlin face in a visible location as shown below. WARNING - Metal components may have sharp edges. Wearing of gloves is recommended. Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 3

4 Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 4

5 Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 5

6 Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 6

7 Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 7

8 SOLAR PANEL ATTACHMENT TO POWERS SOLAR FRAMES RACKING SUPER PURLINS USING THE POWERS SOLAR FRAMES, LLC GATOR-CLAMP 1) Install carriage bolt from top of Gator-Clamp and start lock nut on bolt from bottom of clamp. 2) Attach Gator-Clamps in accordance with engineered plans, a minimum of 2 clamps per module are required for bonding purposes. Additional clapms or other means of module attachment may also be required by the engineered plans. 3) Tighten lock nut till Solar Panel Aluminum Frame, Steel Super Purlin and Gator-Clamp teeth are in full contact with each other. 4) Then add one full turn of the lock nut. 5) Grip loop end of Gator-Clamp to test for stability and tightness. Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 8

9 Bonding Path Diagram (Typical) PERIODIC INSPECTION AND MAINTENANCE It is recommended that the Gator-Clamps and components be visually inspected every 6 months (i.e. Spring and Fall) for any signs of loosening from expansion and contraction due to temperature changes. Adjust and retighten as needed. Note Gator-Clamps are not considered reusable. If for any reason Solar Panels need to be removed or replaced, new Gator-Clamps must be used to reinstall the Solar Panels. When installing new Gator-Clamps for any reason they should not be located in the identical location as the previous clamp. WARNING - Keep copper wire away from aluminum metals. This racking system may be used to ground and/or mount PV modules complying with UL 1703 only when the specific module has been evaluated for grounding and/or bonding in compliance with the included instructions. Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 9

10 SPECIFICATIONS: To be used only in combination with modules that include this specific rack system in their manual. Bonding Qualification testing Completed by TUV Rheinland PTL. L1_PSF140820(RevE)_UL SU 2703 Bonding Tests Completed - Letter of Conformance(31Aug2015). UL2703 Design Load Rating not determined. Site specific design load calculations to be performed by a licensed engineer. Additional load testing performed by Smith Emery Labs; results available upon request. There is no inherent limit to the module size used or the number of modules installed based on this design. See Annex 1 and Annex 2 for installing this PV module mounting solution. See Annex 4, the systems Constructional Data Form (CDF) for detailed descriptions of all parts/components used in this design. Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 10

11 Annex 1 Drawing SK1 ( ) Purlin to Beam Connection Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 11

12 Annex 2 Drawing GMS2 ( ) Ground Mounted Solar Structure Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 12

13 Annex 3 Drawing SSK1 ( ) Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 13

14 Annex 4 Constructional Data Form (CDF) Constructional Data Form (CDF) for Solar Assemblies Project: PSF Report: Certificate: T This Constructional Data Form (CDF) is applicable for Assemblies (e.g. Racking and Ground-Bonding Devices, Trackers, Combiner Box). If greater than 75% of component within model/type is different, then it should be separated into multiple CDFs. The components in type bold with double asterisks (**) only apply to those being submitted as part of an alternate construction design. These additional rows have been added as placeholders for subsequent design variations. These can be left blank until they are applicable. A manufacturer can have multiple types of components listed so long as the combination has been previously certified or it is in the process of being certified through an alternate construction retest. Design Revision(s) (if applicable) Revision No. (Project No.) Revision Details 0 (PSF ) Base qualification 1 (PSF171002, PSF180110) Update listing to UL2703 Edition 1, perform FUI at PSF and add new factory in China. Model Designation Powers Solar Frames Gator Clamp GM-PS#1 Powers Solar Frames Gator Clamp Reference Report Number Certificate Number Certificate Date T Jun Pending Pending License Holder Information: License holder (full address) Production Factory, Warehouse or Installation site #1 (full address) Production Factory, Warehouse or Installation site #2 (full address) Type of product Powers Solar Frames, LLC 4118 E. Elwood St. Phoenix, AZ Powers Solar Frames, LLC 4118 E. Elwood St. Phoenix, AZ Zhejiang Sanlin Metals Products Co. Ltd. No. 189 Changsheng Road Jianshan zhejiang China Canopy Racking System for PV Modules using Clamps for Securement and Bonding GM-PS#1 Structure Trademark Authority name (Client POC) Jason Roland Telephone / jroland@powerssteel.com UL 1741 UL 2703 Applicable standard(s) IEC/UL UL 3703 UL 508A UL 508C Others: UL 1703, UL 9703, other? Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 14

15 Constructional Data Form (CDF) for Solar Assemblies Project: PSF Report: Certificate: T Product Information: (please check only one box) The design being submitted has not been previously certified. The design being submitted is an alternative construction for a design already certified. Design submitted for certification or alternate construction submitted for certification Type name or model number GM-PS#1 Powers Solar Frames Canopy or Ground Mount Racking using Gator Clamp Rated input voltage [V] (N/A for UL Subject 2703) Rated input current [A] (N/A for UL Subject 2703) Rated power [W] (N/A for UL Subject 2703) Maximum system voltage [V] Over-current protection rating [A] 1000V 30A Dimensions (l x w x h) [mm] N/A N/A N/A Product area [m²] (max assembled unit) N/A Expandable system design conforms to any size installation Software version (if appropriate) (N/A for UL Subject 2703) Fasteners Clamp Load Fasteners Slip Factor Threaded Rod Stress Area Mechanical Design Load (Downward/Upward/Downslope) [psf] Module Load Rating (Size/Orientation/Number) Dielectric Voltage Withstand Test (Calculations per UL 2703, Section 6.5 ) Evaluated for Bonding only (Calculations per UL 2703, Section 6.6 ) Evaluated for Bonding only (Calculations per UL 2703, Section 6.7 ) Evaluated for Bonding only Down/Pos(Snow) = Evaluated for Bonding only Max Size = Evaluated for Bonding only Up/Neg(Wind) = Evaluated for Bonding only Landscape/Portrait = Either Downslope(Optional) = Evaluated for Bonding only Quantity= Evaluated for Bonding only (N/A for UL Subject 2703; Calculations per UL 3703, Section 62; Acceptance Test Procedure Verification) Other specifications Evaluated for Bonding only, UL 2703 Sections 13, 17, 18, 22. Installation Manual Gator-Clamp Installation and Inspection Manual, Rev Description of Unit : Canopy or Ground Mount Racking style structure with galvanized steel purlins attached to galvanized steel purlin clips. PV modules mounted to galvanized steel purlins as roof for canopy using serrated clamping device which also acts as bonding path. List of components/subassemblies per Unit Description Manufacturer Type / model 001 INT Super Purlin Powers Technical Data / Ratings / Materials SK1, Interior Double Flange, Rev A G90 galvanized Steel, ASTM A653 Notes / Standard / Certification/Listing (if applicable) Qualified per T A EXT Super Purlin Powers Exterior Single Flange, Rev A G90 galvanized Steel, ASTM A653 Qualified per T End Plate Clip Powers or Others 12ga x 20 G90 galvanized Steel, ASTM A653 Qualified per T Tek Screw DB Fastners or ITW #12 X ¾ DB = Ruspert ITW=Climaseal, ASTM C Qualified per T Beam Powers or Others Varies per project plans Per project plans Per project plans 005 Interior Purlin Clip Powers 4 x 4 x 8 L- Clip, Rev A G90 galvanized Steel, ASTM A653 Qualified per T End Plate Varies Non Structural 12ga Steel Per project plans Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 15

16 Constructional Data Form (CDF) for Solar Assemblies Project: PSF Report: Certificate: T Description of Unit : Canopy or Ground Mount Racking style structure with galvanized steel purlins attached to galvanized steel purlin clips. PV modules mounted to galvanized steel purlins as roof for canopy using serrated clamping device which also acts as bonding path. List of components/subassemblies per Unit Description Manufacturer Type / model 007 End Cap/Clip Powers 101 INT Super Purlin (same as item 001) Powers 12ga Formed, Rev A Technical Data / Ratings / Materials GR55 (55 ksi Yield) G90 Galvanized, ASTM A653 SSK1, Interior Double Flange, Rev A G90 galvanized Steel, ASTM A653 Notes / Standard / Certification/Listing (if applicable) Qualified per T Qualified per T A EXT Super Purlin (same as item 001A) Powers Exterior Single Flange, Rev A G90 galvanized Steel, ASTM A653 Qualified per T Gator-Clamp Powers 16ga Steel, Rev A GR50 G90 Galvanized Qualified per T Carriage Bolt Superior Bolt or others ¼ -20 x 1 ½ Grade 5 Hot Dip Galvanized, ASTM F2329 Qualified per T Nut Superior Bolt or others ¼ -20 Lock NE SERIES Hot Dip Galvanized, ASTM F2329 Qualified per T Other 201 UL 2703 Label Powers GMPS#1 ( ) Gloss polyester weather resistant thermal transfer label Not evaluated in this application 202 Gator Clamp Installation and Inspection Manual Powers Revision = Document to be included with each Installation shipment Evaluated in this application Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 16

17 Constructional Data Form (CDF) for Solar Assemblies Project: PSF Report: Certificate: T UL 2703(2015) First Edition Sections: 13, 17, 18, 22 Signature Page I hereby affirm that the information provided on this form is accurate and complete. I will inform TÜV Rheinland PTL immediately if there are any changes from the responses provided in this form. Signature of authorized representative Date Signature of authorize representative Sponsor (if different from manufacturer) Date Signature of TUV Rheinland PTL representative Date Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 17

18 Drawings of Parts and Components of Qualified System Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 18

19 INT (Interior) Superior Purlin Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 19

20 EXT (Exterior or Edge) Super Purlin Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 20

21 Interior Purlin L-Clip Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 21

22 End Cap/Clip Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 22

23 Gator-Clamp Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 23

24 REVISION HISTORY REVISION DATE DESCRIPTION INITIAL RELEASE UPDATE FOR UL 2703 FIRST EDITION; UPDATED DRAWINGS ON PAGES Powers Solar Frames, LLC, 4118 E Elwood St, Phoenix, AZ (phone ) Page 24