Install Manual GC Pour-in-Place Round Tub Ballasted Ground Galvanized Purlin System - Bottom Mount Configuration 1 and 2 Up Portrait

Transcription

1 Install Manual GC Pour-in-Place Round Tub Ballasted Ground Galvanized Purlin System - Bottom Mount Configuration 1 and 2 Up Portrait CONTENTS I II III IV V VI VII VIII IX X XI GENERAL SAFETY PRECAUTIONS AND RESPONSIBILITY OF INSTALLER MATERIALS AND TOOLS REQUIRED SYSTEM COMPONENTS ASSEMBLY AND INSTALLATION INSTRUCTIONS SYSTEM OVERVIEW MATERIALS, STORAGE AND WARRANTY SITE SELECTION PREVENTATIVE MAINTENANCE ROUND TUB ADDENDUM PRECAST OPTION ADDENDUM

2 I General Please carefully follow this manual to learn how to correctly install the Pour-in-Place Ballasted Ground Galvanized Purlin System (the System ). The 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 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. Please note that this manual may be used for both 1 and 2 up portrait configurations and language between the two is interchangeable.) 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 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 shall become familiar with all applicable safety, health and regulatory requirements before beginning work. Electrical safety notice The System is a mechanical system and contains no live parts. Mechanical installers and electricians shall 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 commercialclass modules installed with the System and assuming a well-equipped five-person crew working 8 hours / day with full task interchangeability: approximately 225 panels and racks per day. 15 men install 1.03 MW per week with 300 watt modules. Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 2

3 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. All regional safety requirements shall be followed when installing the 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 System: String line 48 inch long level Anti-seize may be beneficial to prevent galling for bolts used to mount panels, but is not required 30 foot tape measure Impact Drill with interchangeable drivers 1/4 Drill Bit 7/16 Deep and Short Sockets (1/4 bolts) 9/16 Deep and Short Sockets (3/8 bolts) 7/16 and 9/16 Wrenches Torque Wrench Inclinometer of level with digital degree read out Rack assembly jig made of plywood and 2 x4 wood GameChange Solar System components (see below) Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 3

4 IV System Components The System contains the following parts: (This is the generic manual and it includes all components utilized in all variations of the 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.) North Post (GC361P-N, GC361WP-N or GC361NR-N) South Post (GC 361P-S, GC361WP-S or GC361NR-S) NS Beam (GC862MT) Round Tub (GC281L or GC281XL) Purlin Washer GC126 Horizontal Beam (GC275) Brace (GC283) (if req d) Base Bracket (GC999T) Horizontal Post Channel (GC361P-H, GC361WP-H) EW Purlins (GC63/GC63N) or and Bend Strap (GC871) (if req d) Roll Tie (GC872) (if req d) Roll Strap Purlin Angle (GC874) (if req d) Associated Hardware for Posts (Piles), Braces, Beams, EW Purlins and other components: Flange nuts, and (non-serrated) flange hex bolts; 3/8-16 x 1 inch and 1 ½ inch - magnacoat 3/8-inch washers (both 1 inch and 1 ½ inch diameter must use proper diameters in proper locations)- hot dip galvanized, magnacoat or stainless steel Panel Mounting Hardware: Hex bolts - 1/4-20 x 3/4 inch long - stainless steel (or magnicoat) Flange nuts - 1/ stainless steel (or magnicoat) External tooth star washer - stainless steel (or magnicoat) Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 4

5 V Assembly and Installation Instructions Step 1: Purlins Support Assembly, Ground Prep, Installation of Round Tubs and Purlin Support Assemblies A simple jig is recommended to greatly speed up the assembly of the Purlin Support Assemblies with unistrut or wooden 2x4 s and plywood so that racks can be pre-assembled. Build Purlin Support Assemblies close to their final site location. Transporting full assemblies could damage the materials. If slots on components, then make sure when assembling the Purlin Support Assembly to attach bolts at center of the slots in all cases to leave room for future adjustability. 1.0 Attach Horizontal Post Channel to North and South Post using four 1 inch bolts and four flange nuts. Torque to Spec. 2.0 Attach N-S Beam to posts midway on slots both vertically and horizontally using 1 inch bolts, 1 ½ inch (this is important, must use 1 ½ inch) washers on both sides, and flange nuts. Torque to Spec. Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 5

6 3.0 Install Horizontal Beams near the bottoms of the Posts using four 3/8-16 x 1 inch bolts and four flange nuts. Torque to Spec. 4.0 Install Base Brackets to the middle set of holes approximately 4 inches up from bottom of North Post and South Post using 3/8-16 x 1 1/2 long hex bolts and serrated flange nuts. Leave hardware finger tight. 5.0 Measure the footprint of the array according to the installer s design and site plan. 6.0 Find the edges of the array according to provided design. 7.0 Drop a string line on the southern edge. 8.0 Place Purlin Support Assembly at proper location with posts opening to the east Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 6

7 9.0 For leveling, after EW Purlins have been installed, choose 1 of 3 sets of holes on the posts to attach the Base Brackets to in order to set the height of the system at each post location to even out ups and downs in the system caused by uneven ground conditions. Once preferable height has been obtained tighten hardware to specification. Utilizing adjustment with Base Brackets allows for levelling of EW Purlins Go through GROUND PREP FIRST, then racking frame assembly, then purlin assembly, then leveling step 10.0 Foundation preparation and rebar insertion prior to Round Tub placement: 10.1 Make sure ground is free from debris 10.2 Gravel bed is not required if soil has adequate compaction (95%) and is or will be immediately stabilized. If topsoil is over 3 inches deep or soil has compaction under 95% then gravel bed is preferred to minimize any settlement or movement over time. The System has slots in all axes to allow for adjustability at regular maintenance intervals. However, the amount of movement and thus maintenance related to any movement will be reduced if suggested foundation preparation is followed. Installation of the System on very loose soil which will have substantial movement over time could result in structural damage to the racks if this movement is not countered by adjusting racking to compensate. This could lead to voiding the warranty Rebar is typically not required, since the System has an integrated steel structure inside the Round Tub pouring area. However, rebar insertion holes are provided for additional two or more bars of rebar which may be advisable in severe freeze thaw climates or where substantial ground movement may otherwise be encountered If ground slopes from east to west or from north to south so that amount of concrete in Round Tub will not meet the requirement specified, then place crushed stone or gravel to level the area under directly under where Round Tub will be placed as well as 6 inches outside of this footprint Place Round Tubs as per spacing in the GameChange provided site layout with the south end of the Round Tub touching the string for E-W alignment. Make sure Round Tubs are level. Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 7

8 12.0 Place the Purlin Support Assembly inside the Round Tubs. The Base Bracket and Horizontal Beam fits within the Round Tub such that the frame will be positioned in the Round Tub within an inch tolerance. Make sure no metal part touches Round Tubs. Make sure Horizontal Beam is level. If it is not level, adjust the base bracket up and down by installing to different holes Repeat steps 1.0 through 6.0 to prepare another Purlin Support Assembly and Round Tub assembly. Position the subsequent Purlin Support Assemblies appropriately distance from the previous Purlin Support Assembly per design. Begin installing Purlins while installing supports to insure correct Purlin Support Assembly spacing. Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 8

9 Step 2: Purlin Assembly It is very important that the purlins are aligned and tables are all squared so that panels can easily be attached to purlins after concrete is poured. It can be helpful to set first and last supports with concrete or rocks to hold supports in place while setting rows. Also the use of a dummy post in a concrete filled bucket for north-south alignment can be used to help set rows quickly. 1.0 EW Purlins attach to NS Beams using: 1.1 Two 3/8-inch bolts 1.2 Two 3/8 inch washers (1-inch diameter) 1.3 Two serrated flange nuts 1.4 One Purlin Washer (must use Purlin Channel Washers for 16 gauge Purlins) 2.0 EW Purlins shall be installed facing uphill or downhill as shown in drawing set for each individual system provided as by GameChange. 3.0 Attach first table EW Purlin at southernmost position to the first and second NS Beams using center set of holes for table EW Purlin attachment Direct mounting hardware attachment sequence: Place a Purlin Washer with hole over the hole on the EW Purlin nearest to its wall Insert bolt through Purlin Washer, EW Purlin and NS Beam nearest to EW Purlin wall Attach washer and flange nut under beam (washers may not be required per GameChange direction) Insert bolt through washer, NS Purlin and NS Beam furthest from EW Purlin wall Attach 3/8-inch washer (must use 1-inch diameter) and flange nut under beam (washers may not be required per GameChange direction) Finger Tight on hardware After Panels mounted and Purlins properly aligned, tighten hardware to specification, using driver to turn bolt head. 3.2 Then, noting the length of the Connector EW purlin, attach the second Table southernmost EW Purlin to the third and fourth NS Beams. Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 9

10 3.3 For one up system Install the second EW Purlin on the NS Beam Use 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. 3.4 For two up systems: For completing EW Purlin installation on tables: Install the third EW Purlin up the NS Beam Use 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. 3.5 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), /8-inch washers (must use 1 1/2 diameter) (under both bolt heads) and serrated flange nuts alternatively bolt direction may be reversed. Connector EW Purlin Table EW Purlin (must use 1 1/2 diameter washers) Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 10

11 Picture of table / connector EW Purlin system installed (one purlin may be flipped): or 1.1 Repeat for all table EW Purlins and connector EW Purlins 1.2 Make sure to attach the alternating table EW Purlins and connector EW Purlins starting at one end of row and continue to the other end of the row. 1.3 It is very important that the purlins are aligned and tables are all squared so that panels can easily be attached to purlins after concrete is poured. 1.4 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. 1.5 At end of row install temporary manual bracing to keep the posts plumb and also to allow for a sturdy foundation from which to build the rest of the row. When done with row add manual bracing at other end as well to keeps all posts plumb until pour concrete, after which temporary braces may be removed. 1.6 It is good to pour one Round Tub at end of each row after rows are set up to prevent any movement. Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 11

12 Step 3: Additional Support Attachments (only if required in GameChange specific systems) Attaching the Purlin Connectors (Bend Support, GC871) (if required in GameChange specific systems) 1.0 Purlin Connectors shall be installed on the underside of the Z Purlins approximately midway between two adjacent Beams. The Purlin Connector will include holes for installation. Use 3/8-16 hex bolts and serrated flange nuts. Torque to specification. Purlin Connector (Bend Support, GC871or GC871L) or Attaching the Purlin-to-Beam Supports (Roll Supports, GC873) (if required in GameChange specific systems) 1.0 Purlin-to-Beam Supports 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 Purlin-to-Beam Supports 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. Roll Support (GC873) or Attaching the Purlin-to-Purlin Supports (Roll Tie, GC872-1, GC872-2) (if required in GameChange specific systems) 1.0 Purlin-to-Purlin Supports shall be installed on the EW Purlin legs approximately midway between two EW Purlins specified by on the system design. The Purlin-to-Purlin Supports must be taut; this is very important. Use 3/8-16 hex bolts and serrated flange nuts. Torque to specification. Purlin-to-Purlin Supports Installed: Purlin Connectors (Bend Support, GC872) or Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 12

13 Attaching the Purlin Angle (GC874) (if required in GameChange specific systems) 1.0 Purlin Angles (if required) shall be installed on the underside of the EW Purlins at the holes next to the NS Beams on the uppermost 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 EW Purlins. Use 3/8-16x1 hex bolts and serrated flange nuts. The Purlin Angle Supports must be taut; this is very important. Torque to specification. Purlin-to-Purlin Supports, Purlin Connector, and Roll Ties Installed: Purlin Angle GC874 or Step 4: Installing Rebar (If required) 1.0 If rebar is being installed, slide into pre-punched hole locations (or attach using screws and wire tying if no prepunched insertion holes) on Posts so that rebar is 4 inches below top of lowest end of Round Tub and 4 inches above highest end of Round Tub. Make sure rebar is not within 4 inches of either end of Round Tub. Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 13

14 Step 5: Pouring Concrete 1.0 Level the System before pouring Concrete: The System has significant vertical adjustability which should be done prior to pouring concrete (Self Leveling Technology), which is in addition to the vertical adjustability from moving Purlins to higher or lower slots on Posts. After installation of Purlins has been completed, run a string along Upper and Lower Purlins from east to west across array, or use visual line of sight method. Elevate the Purlins Support Assemblies until Purlins touch the string by placing handfuls of 3/4-inch crushed rock or gravel under Posts to shim them up to level the Purlins. Make sure not to elevate past the point that the Horizontal Beam is within 4 inches of top of the Round Tub. Make sure Horizontal Beam is at least 3 inches above the ground and is level to ensure proper tilt. Also, make sure Round Tub is level within +/- 2% North-South and 5% East-West. If fill is used to level ground under Round Tubs, it is preferable to use rip rap or 3-inch minus to minimize any risk of erosion of fill under Round Tubs. Utilizing adjustment with Base Brackets allows for levelling of EW Purlins When pouring concrete in a Round Tub while using the site specified Round Tub, the surface of the concrete must have a depth of 3" above the highest point on the level Horizontal Beam. The Round Tub can only be 1" difference in elevation from low point to high point of the Round Tub walls. If existing grade cannot meet this standard, gravel can be added under the Round Tub to achieve the standard or a taller walled Round Tub can be used in place of a short walled Round Tub or any combination of the two options. With the taller walled Round Tub, the concrete surface will need to maintain the 3" above the highest point of the leveled Horizontal Beam. Any excess plastic could be cut off at customer s discretion. It is also very important that the purlins are aligned and tables are all squared before concrete is poured, so that panels can be attached to EW Purlins after concrete has cured. 2.0 It is absolutely critical that when pouring concrete the following directions must be followed or Round Tubs will fail: 2.1 Make sure Round Tubs maintain round shape at all times 2.2 Make sure no metal parts are touching Round Tubs 2.3 Make sure Round Tub does not wink into mud on one side cuasing it to deform into non-round shape. If very muddy under Round Tub must place gravel to prevent this from happening 2.4 Do not bang shovel, vibrator or anything else into Round Tub 2.5 Fill Round Tub slowly and carefully so that Round Tub maintains round shape 2.6 Aim flow of concrete at Post Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 14

15 3.0 Make sure to pour concrete immediately if heavy wind (over 30mph) expected as it may blow assembled Purlins and Purlin Support Assemblies over and cause damage or wasted time to set up again. At a minimum make sure to pour a few Round Tubs (or place heavy rocks on top of Horizontal Beam) at the end of each row to prevent heavy wind (over 30mph) from tipping over unfilled Round Tubs/racking. 4.0 If scheduling permits pour a few Round Tubs at end of each row first to give the system most stable starting point to pour the entire system. 5.0 Concrete shall be mixed according to industry standard redi-mix concrete for high strength and long life (4,000 psi minimum), with weight of approximately 4,000 pounds per cubic yard. 6.0 Follow GameChange ballast plan for weight of concrete to be poured into each Round Tub. 7.0 Concrete shall be poured with five inch slump or less. If using pump make sure to use correct add mixture to keep concrete flowing at proper slump. Be careful to follow proper safety protocols with pumps to make sure pressure is correct and there is no danger of blow outs. 8.0 If pouring on non-landfill site, readi-mix trucks can pour directly into the Round Tubs. 9.0 For narrow row spacing or if pouring on weight constrained landfill cap where not possible to use redi-mix truck for pouring, bobcats with pouring buckets (side discharge buckets are especially good because do not have to turn bobcat to pour), concrete pump truck with overhead boom, or grout hoses pulled along the ground may be used. 9.1 Try to drive only in straight lines so as to minimize disturbance of the ground cover. 9.2 Do not drive down same downs, but rather alternate rows as much as possible. This will reduce rutting. 9.3 Make sure water on site so they wash equipment and pouring buckets at end of day so equipment will have no mud or concrete on them so less machinery breakage and less concrete buildup in buckets so faster machine operation and more concrete carried on every load For narrow row spacing a narrow, small bobcat is preferable such as a Bobcat T190, example below: Width with Bucket 68 in Track width 12.6 in Track length 55.2 in sq inches tracks Rated Operating Capacity (SAE) 1900 lbs Operating Capacity at 50% of tip 2715 lbs Loaded Weight 7244 lbs Psi Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 15

16 Bobcat with side discharge pouring bucket ideal for tight rows Overhead or ground hoses good for fast pumping 10.0 Pour / pump concrete mixture into concrete forms to the volume per design. Pour concrete first into middle of Round Tubs. Then use shovel to push it to the two sides. Be careful not to bang shovel into Round Tubs Use vibrator rod following best industry practice. Insert vibrator rod into concrete, move head down to bottom, and then pull it back out again. Be careful not to over vibrate, which can cause aggregate to drop to the bottom, weakening concrete Use a magnesium trowel to trowel wash around legs so precipitation will flow away from legs rather than accumulate around Post penetrations in concrete, be especially mindful to fill area inside leg with concrete so no puddling in that area. It is important to trowel the surface to make it smooth to seal surface best from water Follow best concrete industry practice in pouring concrete, which may include (please consult with your concrete supplier regarding these ideas): 13.1 For direct sunlight exposure on hot days (over 80 degrees F) placement of white poly plastic over concrete surface to allow concrete to retain water longer may be beneficial for long term strength 13.2 If pouring concrete in climates where temperatures may fall to freezing: This may require covering of Round Tubs with frost blankets, or use of accelerators of 1% or 2% content in the mix. Use additives with no chloride or calcium chloride. 6% air entrainment is required for areas where freezing occurs. Hot water may also be required for freezing areas according to industry practice Allow concrete to set to full strength prior to Mounting Modules Wait at least 4 days in above freezing temperatures, more for freezing temperatures before Mounting Modules for 4,000 psi concrete, and 3 days if using 5,000 psi concrete in above freezing temperatures, more for freezing temperatures Weep holes are typically already in Round Tubs provided by GameChange this enables water to drain out. However, if weep holes are not already in Round Tubs, four to six 1-inch diameter holes may be cut with a utility knife, or drilled, evenly spaced around the Round Tub wall. The holes shall be centered 2 inches above the ground level. Please wait at least three days after concrete is poured before making weep holes. Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 16

17 Step 6: Module Attachment Panel Mounting Hardware: Hex bolts - 1/4-20 x 3/4 inch long - stainless steel (or magnicoat) Flange nuts (1/4-20) - stainless steel (or magnicoat) External tooth star washer - stainless steel (or magnicoat) 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, Z 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 Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 17

18 Completed Continuous Systems: Step 7: Grounding The modules, EW Purlins and NS Beams are all bonded together, left to right, so that each row form one single structure. Bonding also continues from the NS Beams to the Posts and all other components via bolted joints. GameChange recommends grounding lug(s) be attached to a ¼ hole drilled 2 ft. above ground level to the back post as shown below: Install Cooper, Burndy, or Eaton UL approved grounding lug with 1/4-inch bolts and serrated flange nuts, or otherwise as in accordance with NEC Article 690 to the end of 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** VI System Overview The System is a simple, affordable, easily installed ground-based solar mounting system. Components are made from galvanized and stainless steel. The 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. Rev GC Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 18

19 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. 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 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 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.for landfills and frost heave susceptible sites where differential settlement is a concern perform a visual inspection of the System annually and resolve any differential settlement by loosening, readjusting and then reattaching. If more adjustment is required than possible with this method then elevate ballast to attain proper adjustment and place rip rap stone bed under ballast. 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 Pour-in-Place TM Round Tub Ballasted Ground Galvanized Purlin System - Install Manual 19