Individual parts and components will vary from system to system. Please reference system specific drawings.

Transcription

1 Mounting InstructionS FS SYSTEM FS System The Schletter FS System for ground mount photovoltaic (PV) installations is specifically designed to meet or exceed applicable IBC, ASCE, and UL standards. For more information on the FS System, please see system brochure. Features Conforms to UL 703 Certified to ULC/ORD STD C703 Electrically Bonded Unit 30 Amp Series Fuse Rating Pre-assembled Components Fully Integrated and Modular Components Includes grounding module clamps The FS System is capable of accommodating nearly any framed or frameless PV module currently on the market. 3 Each FS System is custom designed to meet specific structural load requirements. Included in the FS System are the Rapid5K grounding clamp specifically designed to secure the frame of a PV module to the FS System. 5 In turn, the components and assemblies that comprise an FS System form an electrically bonded unit. While individual components and structural sections will vary between designs, the primary assemblies and installation methods will remain the same Key Components. Foundation post. Head assembly 3. Girder. Strut 5. Locking wedge 6. Purlins 7. Rapid5K TM grounding module clamps MI-008 The FS System is evaluated for electrical bonding only. The FS System meets all IBC and ASCE requirements for structural loading; it has not been evaluated for loading under UL 703. Installer is responsible for verifying that system meets applicable NEC and CSA standards. 3 Maximum number of modules shall not exceed system voltage. Individual parts and components will vary from system to system. Please reference system specific drawings. 5 This racking system may be used to ground and/or mount a PV module complying with UL703 only when the specific module has been evaluated for grounding and/or mounting in compliance with the included instructions. /

2 Mounting InstructionS FS SYSTEM Installation Tools String line with Wood Line Blocks for level foundation post installation Marker/permanent pen Tape Measure Rubber Mallet for locking wedge Carpenter s Square for square girder-to-purlin connection Torpedo Level or Protractor Wrench and/or Socket for all bolted connections Torque Wrench 5 mm 7 mm 8 mm 9 mm Ratchet and/or Rechargeable Power Drill Torx Bit for Rapid5K Module Clamps 3/8 Socket for self-drilling screws TX0 3/8 Socket Hex Head Wrench for standard module clamps 6 mm /

3 FS SYSTEM Mounting InstructionS Foundation Post Installation. Survey Proposed Site Review final drawing at least one week prior to post installation. Drawing will include information vital to the proper installation of the foundation posts such as the embedment depth, post-to-post spacing, slope, rotation, and installation tolerances. inches Please note: Schletter does not provide construction layouts. Tolerance For longer racks, intermediate stakes may be required. Posts are installed vertical to grade. Maximum 7 Installation tolerances: Lateral post placement is ±5.0 Maximum Total Lateral deviation of posts within an array is ±5.0 Post height variation tolerance ±0.50 Embedment depth E-W slope Post verticality tolerance <.0 in all directions ±0.5 Post rotational tolerance <±7.0 Array tilt angular tolerance ±.0 ±7 For East-West slopes greater than 7, contact your Schletter representative Rotation Lateral cantilever Elevation difference between adjacent post Support distance 3 /

4 Mounting InstructionS FS SYSTEM. Post Installation Position each post at the respective installation locations based on the completed stake-out (use a forklift). Position the hydraulic ram (GAYK) at the installation location and lift the post into position beneath the ram head. Level mast of hydraulic ram. Level post using a torpedo level. Advance the post approximately two feet into the subsurface then re-level the post. Advance the post to the embedment depth as shown on the final drawing. Position string lines: bottom string line is used for correct placement of post; top string line indicates correct embedment depth; string is run from the top of the front post to the top of the last post. When installing subsequent posts, ram until the hammer head touches the top string line. Mark each post location using soil nails with flagging Position posts on marked locations (use a forklift) Ram two posts at opposite ends of array for string line Use string lines as guide to determine correct placement and depth of posts Position hydraulic ram and lift post into position beneath ram head Hammer head touching top string line indicates correct depth is reached /

5 FRONT VIEW SCALE : SIDE VIEW FS SYSTEM Mounting InstructionS Mounting the Individual Assembly Groups. Optional Post Splice Verify torque on all bolts. Splices are used to extend the length of a post. Splice location will vary depending on project. Consult project specific drawings.. Head Assembly Install shim plates between post and splice tubing using 3/ bolts, washers, and nuts (front view) 3 Secure head assembly in place using supplied hardware. D D Head assembly has horizontal, vertical, and rotational adjustment to ensure that specified the tilt angle and clearance tolerances are maintained. SCALE : C C Run string line from first to last head piece and adjust in between. Head assembly No Slide Plate, Generation 5 Nut, Flange, Serrated, M, DIN 693, A Screw, HexHead, Mx0, DIN93, A A 693, DIN M0, Serrated, Flange, Nut, Steel, Mild SS 36 (A) /X5CrNi 6063-T T6 Screw, HexHead, M0x30, DIN933, A ITEM QTY PART NUMBER Base, FS Head, Generation 5 SCALE : 5 VIEW ISOMETRIC ASSEMBLED DESCRIPTION MATERIAL WEIGHT PARTS LIST S CHLETTER Inc Spacer, Sleeve, Generation 5, 8mm Washer, 0.5, DIN 739, A FS Head, Top, Generation 5.57 Steel, Mild 6063-T T B B 9 Slide girder onto bolt within the head assembly. A A 5 Align strut with pre-drilled hole in foundation post then secure with provided hardware and tighten. IMPORTANT! Insert locking wedge into the connector using a rubber mallet immediately after installing the girders. After locking wedge is inserted it cannot be removed. SHEET: OF Locking wedge Insert locking wedge into connector after installing girder and strut assembly Verify that assemblies are set in place. CHECKED: BY: DRAWN APPROVED: COMMENTS: CROWN: SIZE: REVISION # WEIGHT OLD PART # : WEIGHT: DIN 768 WT/FT: TOLERANCES: PART NUMBER: TITLE / PROJECT / CUSTOMER: Head Assembly, Generation MATERIAL: 3 MFG: Released STATUS: CRS Solar Mounting Systems SUBCONTRACTOR: SCALE: AS SHOWN 8.75 mm^ AREA: ASSEMBLY NUMBER ENG APPROVAL DATE: MFG APPROVAL DATE: CUSTOMER: CHECKED DATE: //0 DATE: CREATION C BY DH DATE // Place head assembly onto foundation post with M0 bolt, washer, and nut 3. Mount Girder/Strut Assembly Strut-girder connection should be torqued to 0 ft-lbs to avoid compression of the assembly. Installed girder and strut assembly on foundation post 5 /

6 Mounting InstructionS FS SYSTEM. Mount Purlins Align purlins as shown on system specific drawings. Loosen upper mounting clamp on girder. Slide lip of purlin under lower mounting clamp. Verify purlins are installed perpendicular to girder. Secure purlin in place by tightening upper mounting clamp over top lip of purlin. It may be necessary to loosen lower mounting clamp. Mark location with indelible marker prior to loosening. Verify that purlin is positioned correctly before tightening mounting clamps 5. Optional Splice Connection In order to form a longer section, splices may be included to join two purlins. Splices shall be located as specified on project specific drawings. Attach first purlin to girder as stated in Step. Insert splice piece halfway into the end of first purlin section and secure in place using one self-drilling screw. Loosely attach second purlin section to girder and slide over splice piece that is connected to first purlin. Secure purlin in place using one self-drilling screw. Verify purlin is installed in correct location as specified on the project specific drawings. Secure assembled purlin in place by tightening all upper mounting clamps. Installed purlin (side view) Insert splice into end of two purlins and secure in place using self-drilling screws 6 /

7 FS SYSTEM Mounting InstructionS 6. Install Overcurrent Protection Device (grounding) Shares bolt that connects strut to post. Remove serrated flange and install grounding lug; torque to specification. Accommodates stranded or solid copper wire ( gauge to gauge). Must use bare copper wire to connect to the grounding lug. If using insulated grounding wire, remove at least inches of insulation to expose copper wire. Loosen or remove top portion of grounding lug and insert grounding wire into appropriate groove Grounding wire must extend through grounding lug by at least / Ground Path Diagram Module Frame Grounding Clamp Purlin Splice Purlin Girder Head Assembly Foundation Post 7 /

8 Mounting InstructionS FS SYSTEM Optional Accessories. Bonding Jumper Electrically bonds adjacent systems forming a continuous ground path. Available in 6-inch to 8-inch lengths. Used for expansion joints or other breaks in the racking system.. Cable Management If cable management was ordered with the system, install before modules are in place. Bonding jumper connects directly to purlin Bonding jumper can be installed on top channel of purlin using M8 hardware Snap ProKlip-Multi 8 into M8 top channel on purlin. ProKlip-Q (90-00) ProKlip000-P (90-00) Snap ProKlip000-P or ProKlip-Q cable clip onto side of S Purlin. ProKlip-Multi 8 ( ) Attach cable duct (80-000) against side of purlin with selfdrilling screws Combiner box mount is installed against exterior end of foundation post 3. Micro-Inverters Mark approximate centers of each module on the rack assembly for micro-inverter placement Mount one micro-inverter at each marked location using the provided hardware mounting kits Allow a minimum of 0mm between roof and bottom of inverter. Allow a distance of 5mm between back of module and top of inverter Torque to the appropriate value Enphase: 9 N-m (80-85 in-lbs) Darfon: 9 N-m (80 in-lbs) AEconversion: 5 N-m Attach micro-inverter to top channel of rail using provided hardware kits 8 /

9 FS SYSTEM Mounting InstructionS Module Mounting. Position Modules 0 mm Position end clamps approximately 0 mm from end of purlin. Position first module and secure prepositioned end clamps; do not tighten. End (left) and middle (right) grounding clamps Attach middle clamps to purlin on the exposed side of first module. Place second module and secure using the middle clamp; do not tighten. Repeat until end of row, then secure exposed side with end clamps. Rapid5K TM Grounding Clamp Horizontal module orientation. Secure Modules Verify that the module clamp is fully engaged on the purlin and that the module clamp is aligned with the module frame. Secure in place to specified torque. When mounting modules, please observe the clamping points specified by the module manufacturer. Vertical module orientation 3 mm max..5 mm maximum middle clamp to module offset 5 mm If adjustable end clamps are provided, slide attachment on to desired height. Allowable gaps between modules 9 /

10 Mounting InstructionS FS SYSTEM Torque Specifications and Tolerances Systems are specifically designed for each project. Please reference the specific project drawing for allowable tolerances and recommended torque for each size of bolt used in the system. In the event of deviation from approved drawings, contact Schletter immediately. Equipment Grounding Torx Bolt for Rapid5K Module Clamps N-M 0.5 FT-LBS M6 and / Bolt 6 N-M.5 FT-LBS M8 and 5/6 Bolt N-M 0.5 FT-LBS M0 and 3/8 Bolt 30 N-M 3 FT-LBS M and / Bolt 50 N-M 37 FT-LBS M6 and 5/8 Bolt N-M 89 FT-LBS M0 and 3/ Bolt N-M 80 FT-LBS Note: Recommended speed for installation of self-drilling / diameter is RPMS. Many PV installations contain more than one mounting system. Such cases call for electrically bonding each of the different manufacturers systems. Since individual racks are fully bonded units it is only necessary to connect individual racks together from one single point to another single point. 6 Only use stainless steel hardware when connecting harnesses or jumpers to the mounting system. Take care to prevent copper wires from directly contacting aluminum surfaces as this will cause corrosion. For this purpose, Schletter offers a bonding jumper (see page 8). The PV INSTALLER of Schletter s electrically bonded FS system must provide the components necessary for the final connections to the grounding electrode system. Typically the installation will incorporate a grounding electrode (ground rod), appropriately sized copper wire, rated wire connectors, and grounding lugs which are rated for this purpose. The PV INSTALLER must follow all manufacturers installation literature. Installation must comply with all applicable NEC/CSA sections including but not limited to; NEC 50 (Grounding and Bonding), NEC 690 (Solar Photovoltaic Systems), CSA. (Safety Standard for Electrical Installations), and all other applicable state, and local electrical code requirements. PV INSTALLER shall be fully responsible for all connections between Schletter s bonded FS system and PV grounding electrode system. Equipment grounding conductors shall be no less than AWG (copper) or AWG (aluminum). Equipment grounding conductors can be connected to any exposed metallic portion of rack system provided that: a. connection area is sufficiently sized b. dissimilar metals are not in direct contact c. connection does not interfere with other components d. connection is protected from damage Safety Precautions Follow proper installation and safety procedures at all times. Edges of parts may be sharp. Follow proper lifting procedures. 6 Schletter recommends two bonding jumpers to connect separate systems for redundancy. 0 /

11 FS SYSTEM Mounting InstructionS Maintenance Yearly inspection of system should be conducted to maintain optimal performance. Visually inspect for signs of damage, wear, corrosion, or movement. Replace any affected components immediately. Check for loose wiring Check mechanical details of the structure: -At least % of bolted connections must be checked using a calibrated torque wrench. The torque wrench must have a display or be a click type torque wrench. -Torque wrench should be set at 50% of the intended tightening torque. Check is successful if the bolt cannot be loosened. -If >0% of the checked bolted connections are loose, the check has to be increased by a factor of five. -If more than 0% of connections are still loose, all bolted connections much be checked. -Tighten to specified torques Requirements per ASME B07 and AISC WARNING: Risk of death by electric shock Maintenance should only be performed by qualified personnel. For more information on cable management, please contact us at: Schletter Inc. 00 Commerce Center Drive Shelby, NC 850 Call: (888) Fax: (70) info.us@schletter-group.com Schletter Canada Inc. 38 Devon Drive Windsor, ON N8X L3 Call: (59) Fax: (59) mail.canada@schletter-group.com Torx is a registered trademark of the Camcar Corp. division of Textron Industries. /

12 Mounting InstructionS FS SYSTEM Approved Module Manufacturers Bonding and Grounding Canadian Solar CS6X P CS6X-P-FG CS6K-P-FG CS6K-M CS6K-M AB CS6P-P CS6P-P-SD CS6V-M ET Solar ET-M BB ET-M WW WB ET-M BB ET-M WW WB ET-P BB ET-P WW WB ET-P BB ET-P WW WB Hanwha Q Cells Q.PRO BFR G G. G.3 Q.PLUS BFR G. Q.PRO G Q.PLUS G Q.PRO L G. Q.PLUS L G. G. Q.PEAK-G. G./MAX Q.PEAK BLK G. Q.PEAK L G. HSL7P6-PC-3-xxxT Heliene Heliene M Heliene P Hyundai Solar HiS-M TI HiS-S TI HiS-M RG HiS-S RG Jinko Solar JKM75P-60 JKM330P-7 Eagle 60 7 Eagle PERC Eagle Black 60 7 JKM75PP-60-V JKM330PP-7-V JKM70P-60-V JKM30P-7-V Eagle MX JK07A JK07B JKM65PP-60 Kyocera KD60 65GX-LFB KU MCA KU ZPA KU60-6MPA LG LGxxxNC-G LGxxxNW-G LGxxxSC-G LGxxxSW-G LGxxxNK-G LGxxxNC-B3 LGxxxNW-B3 LGXXXNC-A5 LGXXXSC-A5 LGXXXNW-A5 LGXXXSW-A5 REC Solar REC PE REC PE BLK REC PE7 REC TP REC TP7 SolarWorld Sunmodule SW 80 MONO RHA Sunmodule SW 50 POLY R6A Sunmodule SW 50 MONO R6A Sunmodule SW 00 POLY RGP Sunmodule Plus SW MONO Sunmodule Plus SW MONO (5-busbar) Sunmodule Plus SW MONO BLACK (5-busbar) Sunmodule Plus SW MONO BLACK Sunmodule Pro-Series SW 60 POLY WOB Sunmodule Protect SW MONO BLACK Sunmodule SW XL MONO Talesun TP660 67M TP660 67P TP660 67P(H) TD660M TD660P Hipro M95+ TP660M Hipro M350+ TP67M PID ZERO TP67M FEATHER.0 TP660P Trina TSM-PD TSM-PD05 TSM-PD05.08 TSM-PD05.05 TSM-DDA(II) TSM-PEG5 TSM-PEG5.07 TSM-PEG TSM-PEG0.07 Yingli Green Energy YL300C 95C 90C 85C 80C 75 C-30b YL90D 85D 80D 75D 70D-30b L30D 335D 330D 35D 30D 35D- 36b YL75P 70P 65P 60P 55P 50P- 9b YL60P 55P 50P 5P 0P-9b YL35P 30P 35P 30P 305P 300P- 35b Approved Micro-Inverters Enphase M5 M50 Darfon G30 AEconversion INV /