Installation Manual. Roof Tech,Inc. 5/2014. Contents

Transcription

1 5/2014 Installation Manual Contents Introduction 1 Installation Safety 2 ools & Supplies Required For Assembly 3 1.Installation on rafter 4 2.Installation on deck 16 3.Panel installation 29 Roof ech,inc. 92 Hamilton Dr.Suite A Novato,California EL (415)

2 Introduction Please review this manual thoroughly before installing your Roof-ech system. Aside from reading this manual, please review the PE Stamped engineering certification for the Roof-ech [E]Mount Solar product for your State. his manual provides support documentation for the installation of Roof-ech s [E]Mount product. We recommend the installer to carefully review the instructions provided by the solar PV module manufacturer and become acquainted with OSHA s safety procedures prior to installing the solar PV system. he installer is solely responsible for: Handling and installing the solar PV modules according to the manufacturer s instructions Complying with all applicable local or national building codes, standards and industry best practices including any code that may supersede this manual Ensuring that Roof-ech and other products are appropriate for the particular installation and the installation location Ensuring that the roof, its rafters, connections, and other structural support members can support the array under all code level loading conditions Using only Roof-ech parts and installer-supplied parts as specified by Roof-ech (substitution of parts may void the warranty and invalidate the letters of certification Verifying the strength of any alternate mounting used in lieu of the anchoring screws Maintaining the waterproof integrity of the roof Ensuring safe installation of all electrical and mechanical aspects of the PV array Ensuring correct and appropriate design parameters are used in determining the design loading used for design of the specific installation. Parameters, such as snow loading, wind speed, exposure and topographic factor should be confirmed with the local building official or a licensed professional engineer. 1

3 Installation Safety he installation process requires working on sloped and elevated building surfaces, in out-door weather conditions, using tools and heavy components designed for the generation of electricity. Use properly anchored fall protection equipment Use caution to prevent objects from falling or dropping off the roof area Cordon off ground areas directly beneath the roof work area when possible Always use personal protection equipment such as safety glasses, gloves, etc. as necessary Do not perform installations in excessively wet, windy, or inclement weather conditions When working in hot weather, work crews should take care to prevent symptoms of over-heating or dehydration Use proper lifting and carrying techniques when handling heavy components at the job site. If conditions are challenging for moving PV modules to the roof area, use a mechanical lift Follow best practices when working around high-voltage electrical equipment Do not anchor fall protection equipment to roof mounts, or any other inappropriate roof structure Customer Support If you need assistance at any point of your installation or have suggestions on how can we improve your experience, call Roof-ech customer support (415)

4 ools & Supplies Required For Assembly ools needed for building the array Hex bit socket (13 mm):long socket Hex bit socket (8 mm) Measuring tape Chalk line Chalk Phillips/flat head screwdriver Rubber mallet Weather resistant caulking orque wrench Butyl tape Scissors orque Values For Dry Bolts: 12 Nm applied to middle and end clamps. Module Clamp able Clamp H:Panel frame Item ID Discription 31mm RM-E31BK-B-00 R-[E]Mount End Clamp 31mm kit BOX(40 ea.) 35mm RM-E35BK-B-00 R-[E]Mount End Clamp 35mm kit BOX(40 ea.) End Clamp 40mm RM-E40BK-B-00 R-[E]Mount End Clamp 40mm kit BOX(40 ea.) 46mm RM-E46BK-B-00 R-[E]Mount End Clamp 46mm kit BOX(40 ea.) 50mm RM-E50BK-B-00 R-[E]Mount End Clamp 50mm kit BOX(40 ea.) 31mm-40mm RM-MCB45BK-B-00 R-[E]Mount Middle Clamp kit CB45 BOX(40 ea.) Middle Clamp 46mm RM-MCB50BK-B-00 R-[E]Mount Middle Clamp kit CB50 BOX(40 ea.) 46mm-50mm RM-MCB55BK-B-00 R-[E]Mount Middle Clamp kit CB55 BOX(40 ea.) Grounding Setup All electrical installation and procedures should be conducted by skilled, licensed and bonded electricians. All work must comply with all national, state and local installation procedures, product and safety standards. hese standards include but are not limited to applicable National Electrical Code NEC 690 and NEC 250, National Electrical Installation Standards (NEIS M ), UL Standards, and OSHA Regulations. Note:Maximum Series Fuse Rating of 20A. Grounding,Bonding lugs and Straps are not provided by Roof ech Inc. 3

5 1.Installation on rafter 1 Items [E]Mount bracket set Item [E]Mount Screw Butyl spacer Item quantity Caulking Item 1 Caulking Recommended product Henry:208R,209,925(Black) Geocel:S2,S4(Black) 1 3 3Clamp kit Item 1 Middle clamp 2 End clamp 3 Panel spacer 4 Bonding plate 5 Carriage bolt M8-** 6 Cable holder he nuts in RM-MCB45BK-B-00 are silver and black. he nuts in RM-MCB50 and 55BK-B-00 are black. 4Shims Item 1 Shim 2 Self tapping screw

6 2 Installation 1)Aligning the array with a chalk line Example(3 3) 3 (1/16inch) Length of the panel 1/8inch (3mm) Length of the panel 1/8inch (3mm) Length of the panel (1/16inch) 1 3/16inch (30mm) 3 1/2inch 1 3/16inch (90mm) (30mm) 5/8inch Width of the panel Width of the panel Width of the panel (15mm) 5/8inch (15mm) [E]Mount bracket PV panel 1 0 R R R R R R Note:Minimum distance 1/8 inch (3mm) between panels. Showing plan is one of installation idea to make a drawings. 5

7 1 Chalk line according to the installation plans, where the modules will be mounted. (ⅰ)Line 0:For the first row of brackets. Shall be 3/16 inch(5mm) lower from the upper composite shingle. 0 1 (ⅱ)Line 1:Lined 3 1/2 inch (90mm) lower from Line O. It delineates the location of the carriage bolt for the first row of modules. 1 0 (ⅲ)Line :Shall be 1 3/16 inch (30mm, equivalent to the width of Middle spacer.) added to the width of the panel for a landscape or the length for portrait installation. Measured from 1. (ⅳ)Line :Shall be the length (landscape install) or width (portrait install) of the panel size + 1/8 inch (3mm). Or preferred space between rows. he above procedure delineates the lay out of the array. 3 1/2 inch(90mm) 1 0 3/16 inch(5mm) =Width of the panel + 1 3/16 inch(30mm) 6

8 2 Aligning the [E]Mount brackets. Choose the rafter most suitable for the array,then make chalk lines to mark their center. (ⅰ)Line R:Rafter location 0 1 R R R R R R R R 1 0 Recommended installation area according to the PV panel manufacturer instructions. Recommended installation area according to the PV panel manufacturer instructions. PV panel Rafter R R Length of the panel + 1/8 inch(3mm) 7

9 2) Installation [E]Mount bracket. 1Shows the spot where the [E]Mount brackets will install on Line O. Also,shows the spot where [E]Mount brackets will be installed on Line R. R Marking 3/16 (5mm) 0 Marking R 3/16 (5mm) 0 8

10 2 Chose "A" or "B" installation at each bracket location. [E]Mount Eave side 4 11/16 inch(120mm) 1/2 inch(13mm) 1/2 inch(13mm) 2 1/2 inch (65mm) 1 3/16 inch (30mm) :Clamp mounting area 1 Installation starts from (First row of Brackets) Composite shingles edge 3/16 inch(5mm) 3/8 inch(10mm) 3/8 inch(10mm) Screws shall be installed at a minimum of 3/8 inch (10mm) from the edge of the shingle. [E]Mount R Installation A R Installation B Attention Minimum clearance between mounting screws and the edge of the roofing shingle shall be 3/8 inch(10mm). 9

11 3Adjust the butyl tape layer to match the height of the upper shingle. When there is a gap, a slit,or a difference in the height, in the mounting location of [E]Mounts, use additional butyl tape. [If there is slit on shingle. ] When there is a slit in the installation spot,cut the butyl tape to match and place it in the slit. he slit must filled with butyl tape. 3/16 (5mm) 0 When there is a slit on the upper side of bracket, cut the butyl tape to match the slit shape. And apply caulking around the butyl tape. Caulking Please try to install bracket more than 2 inch away from slit. If possible, avoid placing the bracket within less than 2 inch from the slit. 2 inch (50mm) 2 inch (50mm) Screw position If screw installation comes to closer to slit (less than 2 inch), fill the slit with butyl tape. 2 inch (50mm) 2 inch 2 inch (50mm) (50mm) Screw position 2 inch (50mm) 10

12 [If there is some gap and layer where bracket install.] When there are gaps in the position to install,cut butyl tape at the shape of the gap and place it. Note:Each bracket comes with butyl tape installed, and is supplied with an additional tape. 3/16 (5mm) 0 Attention Peel off the protection paper from both sides of butyl tape. 11

13 [Case 1] Use Butyl tape to level the surface of the composite shingle roof. Cut "teeth" where Bracket shall install Flush with shingle Note:Do not splice the butyl tape. 2 layers of butyl tape 1 layer of butyl tape 12

14 [Case 2] Build layers of butyl for the Bracket to be mounted over the teeth region of composite shingle roofs. A maximum of 4 layers are acceptable. Layer 1 is built on the bottom of the Bracket already. he Following layers must be cut to shape to cover the surface of the bracket at each location,assuring a completely flat surface. 2 layers of butyl tape 1 layer of butyl tape Note:Do not splice the butyl tape. 13

15 4 Peel off the protective paper from the butyl tape. Attention Do not leave any protective paper on the surface of the butyl tape,it can cause an improper seal and may allow water intrusion under the bracket. [E]Mount Butyl tape Release paper 5 Installing [E]Mount brackets. Use 8mm x L110mm socket to set the 5.0 x 60mm Lug screw. Make sure the installation is on the rafter located between the line that interesects Line.(Pg.4) Place the [E]Mount brackets with butyl tape and make sure the butyl attaches well to the roofing surface. Attention Note:[E]Mount has an ordinal direction to be installed. he larger hole for the clamp bolt should be towards the top of the roof. Screw Ridge Composite shingles [E]Mount [E]Mount Eave Note:5.0mm x 60mm wood screw must hit the rafter. Chalk line R Eave 14

16 Attention Note:Do not set the 5.0mm x 60mm screw too tight. he washer should not move. Socket or Phillips head Washer Washer Rubber washer Rubber washer Bad Good Bad [E]Mount (Note:Setting the screws too tight screws may cause the roof to deform.) 6 Caulk around [E]Mount brackets. Caulk the top and each side edge of [E]Mount. Cover the exposed butyl tape with caulking. Do not caulk the bottom of the bracket. Ridge [E]Mount Caulking Composite shingles Eave Caulking Eave Go to 3.Panel installation 15

17 2.Installation on deck 1 Items [E]Mount bracket set Item Item quantity [E]Mount 2 Screw Butyl spacer Caulking Item 1 Caulking Recommended product Henry:208R,209,925(Black) Geocel:S2,S4(Black) 1 3 3Clamp kit Item 1 Middle clamp 2 End clamp 3 Panel spacer 4 Bonding plate 5 Carriage bolt M8-** 6 Cable holder he nuts in RM-MCB45BK-B-00 are silver and black. he nuts in RM-MCB50 and 55BK-B-00 are black. 4Shims Item 1 Shim 2 Self tapping screw

18 2 Installation 1)Aligning the array with a chalk line Example(3 3) 3 (1/16inch) Length of the panel 1/8inch (3mm) Length of the panel 1/8inch (3mm) Length of the panel (1/16inch) 5/8inch (15mm) [E]Mount bracket PV panel 1 3/16inch (30mm) 1 3/16inch (30mm) 3 1/2inch (90mm) Width of the panel Width of the panel Width of the panel 5/8inch (15mm) 1 0 M M M M M M Note:Minimum distance 1/8 inch (3mm) between panels. Showing plan is one of installation idea to make a drawings. 17

19 1 Chalk line according to the installation plans, where the modules will be mounted. (ⅰ)Line 0:For the first row of brackets. Shall be 3/16 inch(5mm) lower from the upper composite shingle. 0 1 (ⅱ)Line 1:Lined 3 1/2 inch (90mm) lower from Line O. It delineates the location of the carriage bolt for the first row of modules. 1 0 (ⅲ)Line :Shall be 1 3/16 inch (30mm, equivalent to the width of Middle spacer.) added to the width of the panel for a landscape or the length for portrait installation. Measured from 1. (ⅳ)Line :Shall be the length (landscape install) or width (portrait install) of the panel size + 1/8 inch (3mm). Or preferred space between rows. he above procedure delineates the lay out of the array. 3 1/2 inch(90mm) 1 0 3/16 inch(5mm) =Width of the panel + 1 3/16 inch(30mm) 18

20 2 Locate the [E]Mount brackets. Make a chalk like according to the PV module installation instruction. 0 (ⅰ)Line M:Center line of [E]Mount 1 M M M M M M M M 1 0 Recommended installation area according to the PV panel manufacturer instructions. Recommended installation area according to the PV panel manufacturer instructions. PV panel Rafter M M length of the panel + 1/8 inch(3mm) 19

21 2) Installing the [E]Mount bracket 1Mark the location, which is the intersection of O and M. (op of the [E]Mount bracket, on the first row.) Marking M 3/16 (5mm) 0 Marking M 3/16 (5mm) 0 20

22 2 Chose "A" or "B" installation at each bracket location. [E]Mount Eave side 4 11/16 inch(120mm) 1/2 inch(13mm) 1/2 inch(13mm) 2 1/2 inch (65mm) 1 3/16 inch (30mm) :Clamp mounting area 1 Installation starts from (First row of Brackets) Composite shingles edge 3/16 inch(5mm) 3/8 inch(10mm) 3/8 inch(10mm) Screws shall be installed at a minimum of 3/8 inch (10mm) from the edge of the shingle. [E]Mount M Installation A M Installation B Attention Minimum clearance between mounting screws and the edge of the roofing shingle shall be 3/8 inch(10mm). 21

23 3Adjust the butyl tape layer to match the height of the upper shingle. When there is a gap, a slit,or a difference in the height, in the mounting location of [E]Mounts, use additional butyl tape. [If there is slit on shingle. ] When there is a slit in the installation spot,cut the butyl tape to match and place it in the slit. he slit must filled with butyl tape. 3/16 (5mm) 0 When there is a slit on the upper side of bracket, cut the butyl tape to match the slit shape. And apply caulking around the butyl tape. Caulking Please try to install bracket more than 2 inch away from slit. If possible, avoid placing the bracket within less than 2 inch from the slit. 2 inch (50mm) 2 inch (50mm) Screw position If screw installation comes to closer to slit (less than 2 inch), fill the slit with butyl tape. 2 inch (50mm) 2 inch 2 inch (50mm) (50mm) Screw position 2 inch (50mm) 22

24 [If there is some gap and layer where bracket install.] When there are gaps in the position to install,cut butyl tape at the shape of the gap and place it. Note:Each bracket comes with butyl tape installed,and is supplied with an additional tape. 3/16 (5mm) 0 Attention Peel off the protection paper from both sides of butyl tape. 23

25 [Case 1] Use Butyl tape to level the surface of the composite shingle roof. Cut "teeth" where Bracket shall install Flush with shingle Note:Do not splice the butyl tape. 2 layers of butyl tape 1 layer of butyl tape 24

26 [Case 2] Build layers of butyl for the Bracket to be mounted over the teeth region of composite shingle roofs. A maximum of 4 layers are acceptable. Layer 1 is built on the bottom of the Bracket already. he Following layers must be cut to shape to cover the surface of the bracket at each location,assuring a completely flat surface. 2 layers of butyl tape 1 layer of butyl tape Note:Do not splice the butyl tape. 25

27 4 Starting eave edge installation [E]Mount brackets shall be installed per installtion A.(Pg.18) Composite shingles 3/16inch 4 11/16inch (5mm) (120mm) 3 1/2inch (90mm) Chalk line Chalk line 0 M Eave Chalk line 1 5 Peel off the protective paper from the butyl tape. Attention Do not leave any protective paper on the surface of the butyl tape,it can cause an improper seal and may allow water intrusion under the bracket. [E]Mount Butyl tape Release paper 26

28 6 Installing [E]Mount brackets. Place the [E]Mount bracket to the specified position. Using 8mm L110mm socket, set the bracket with 4 each mm Lug screws. After completing process,make sure [E]Mount bracket is securely fit to the composite shingle. Attention Note:[E]Mount has an ordinal direction to be installed. he larger hole for the clamp bolt should be towards the top of the roof. Ridge Screw Composite shingles [E]Mount [E]Mount Eave Chalk line M Eave Attention Note:Do not set the 5.0mm x 60mm screw too tight. he washer should not move. Socket or Phillips head Washer Washer Rubber washer Rubber washer Bad Good Bad [E]Mount (Note:Setting the screws too tight screws may cause the roof to deform.) 27

29 7 Caulk around [E]Mount brackets. Caulk the top and each side edge of [E]Mount. Do not caulk the bottom of the bracket. Ridge [E]Mount Caulking Composite shingles Eave Caulking Eave Go to 3.Panel installation 28

30 3. Panel installation 1)Install the first row Carriage bolt 1Slide the carriage bolt from the opened top. Place the bonding plate and handtighten it. Bonding plate shall be installed with the square section closer to the ridge,and with the tongue pointing down toward the shingles. Nut Bonding Plate Nut Bonding plate [E]Mount ongue Carriage bolt [E]Mount 1 3/16inch (30mm) 2Line bolts up on a straight line, based on a bolt placed at the very ends of the brackets. 2 Align the carriage bolts with the lowest. 3Set the carriage bolt and nut at the far edges to torque 110 inch lb(12nm). 2 4Line up the bolts in a straight line by using a string-line. 5Once every bolt is lined up, pre-tighten up each set. Leveling string 4 29

31 6Check the level of [E]Mount bracket. If there is difference between brackets, add the shims and bonding plate to set the level. Maximum of 3 shims per bracket. Nut Bonding plate Shims Optional(Max 3 shims) Bonding plate 7If shims are used for leveling, set the self tapping screw 5.0 x 16 to secure the shims. Self tapping screw Carriage bolt Bonding plate Shims Optional(Max 3 shims) Bonding plate If 1 or 2 shims are used,then bend the upper bonding plate tongue flat. Attention Note:It is important to replace the bonding plate once it is used such as a panel replacement for instance. Self tapping screw shall be fixed to the shims when more than 2 shims are placed. his screw is needed as bonding path. 8 After establishing your line, tighten all carriage bolts to 110 inch lb(12nm). 9Install the end clamp with star conical washer and nut as it is shown on picture. Hand-tighten the nut,but keep clamp loose for the frame to slide in. Nut Star conical washer End clamp Nut Star conical washer End clamp 30

32 10Place the PV panel on the [E]Mount bracket. End clamp Solar panel 11 Make any adjustment and tight the nut to 110 inch lb(12nm). Long socket Solar panel 31

33 2) Installing the middle clamp bracket 1As it is shown on picture,place the panel spacer and bonding plate onto the carriage bolt. Slide it in to the [E]Mount bracket from the upper side of the bracket. Note:Bonding plate must be placed in right direction as it is shown. Nut( ) Star conical washer Panel spacer Bonding plate Carriage bolt Nut( ) Star conical washer Panel spacer Bonding plate Solar panel ongue Attention ( )Silver:RM-MCB45BK-B Black :RM-MCB50 and 55BK-B Solar panel 2Slide the panel spacer until it is flush to the panel frame. Nut( ) Star conical washer Panel spacer Bonding plate Shims Optional(Max 3 shims) Bonding plate Panel spacer If shims are needed,2 bonding plates are used. Maximum of 3 shims per bracket. 32

34 3If shims are used for leveling, set the self tapping screw 5.0 x 16 through the shims. Self tapping screw Bonding plate Shims Optional(Max 3 shims) Bonding plate 4 After setting it leveled, tighten the panel spacer to 110 inch lb(12nm). 5Set the panel in place and install Middle clamp with a nut and a star conical washer. he torque must be 110 inch lb(12nm). Nut Star conical washer Middle clamp Nut Star conical washer Middle clamp 33

35 3)Install top end clamps 1Slide the Carriage bolt from the opened top. Place the bonding plate. Bonding plate must be placed in the shown direction. Carriage bolt [E]Mount Bonding plate ongue Bonding plate If shims are needed,place it under the bonding plate. Maximum of 3 shims per bracket and add a bonding plate. Bonding plate Carriage bolt Attention Note:It is important to replace the bonding plate once it is used such as a panel replacement for instance. 2If shims are used for leveling, set the self tapping screw 5.0 x 16 to its place. 34

36 3Place the end clamp and tighten it to 110 inch lb(12nm). Star conical washer End clamp Star conical washer End clamp Bonding plate Shims Bonding plate Slide the bonding plate in place with the carriage bolt. 35

37 4) Cable management options Cable holder 1[E]Clamp can fit into the [E]Mount brackets as it is shown in the picture. 2Place the cables into the holding area and close the clamp. ou can hear a click when it is secured. Note:If the cable clamp need to be opened,simply pinch and pull by hand. Also,it can be easily removed from the bracket simply slide it out. Cables Note:Cable holder can hold 3 to 4 cables depends on the thickness of cables. AWG size 8, Cable number )Mounted on the Module frame 1Cable holder can fit through a φ6.6mm hole on panel frame. Cable holder can be separated from the bottom part(grommet). Cable holder φ6.6 PV panel 36

38 6) Cable mounting bracket (Optional) Cable mounting bracket Mounting screw Cable mounting bracket Cable holder Mounting screw Cable holder PV Cable Cable holder Optional Cable mounting bracket Item Cable mounting bracket Mounting screw

39 7) Grounding Setup All electrical installation and procedures should be conducted by skilled, licensed and bonded electricians. All work must comply with all national, state and local installation procedures,product and safety standards. hese standards include but are not limited to applicable National Electrical Code NEC 690 and NEC 250,National Electrical Installation Standards(NEIS M ),UL Standards,and OSHA Regulations. [E]Mount hardware is classified to UL 2703 and it is to be used with UL 1703 listed PV modules and must be installed per PV module manufacturer's installation instructions. We recommend the use of either the Weeb-6.7 or Ilsco SGB-4 Grounding lug with a minimum 10AWG solid copper grounding conductor. Grounding lug to be installed per manufacturers instructions,using the manufacturers provided hardware. Example1 Solar panel WEEBLug-6.7 WEEB teeth towards module frame Module mounting hole 38

40 Example2 Solar panel ILSCO SGB-4 Example3 [E]Mount ILSCO SGB-4 Cable holder Cable mounting bracket PV Cable 39

41 WEEBLug-6.7 ILSCO SGB-4 In order to properly ground the PV modules and the [E]Mount to the equipment ground,a grounding lug or lay-in lug must be attached to a PV module at the end of each row. Note:Maximum Series Fuse Rating of 20A. Grounding,Bonding lugs and Straps are not provided by Roof ech Inc. 40

42 Grounding Lugs,Bonding Lugs and Bonding Straps 1) BURND WEEB LUG 1 WEEB-LUG WEEB-LUG-6.7AS 3 WEEB-LUG WEEB-LUG-8.0AS 5 WEEB-LUG-8.2MS 6 WEEB-LUG-15.8 WEEB-BONDING JUMPER 1 WEEB-BNDJMP6.7 2 WEEB-BNDJMP6.7AS 3 WEEB-BNDJMP8.0 4 WEEB-BNDJMP8.0AS 5 WEEB-BNDJMP8.2MS 6 WEEB-BNDJMP9 7 WEEB-BNDJMP12 8 WEEB-BNDJMP24 9 WEEB-BNDJMP36 2) ILSCO ILSCO Dual Rated Lay-In Ground Lug type SGB 1 SGB-4 ILSCO Dual Rated Lay-In Ground Lug type GBL 1 GBL-4 2 GBL-4SS ILSCO Copper Lay-In Ground Lug Direct Burial type GBL-DB 1 GBL-4DB 2 GBL-4DB-14 3 GBL-4DB 4 GBL-4DB-14 41

43 May.29,2014