INSTALLATION MANUAL AWNING SYSTEM INSTALLATION INSTRUCTIONS ALL VERTICAL WALLS
TABLE OF CONTENTS Table of Contents... 3 Components... 4 System Components... 6 Attachment Components... 7 Module Compatibility... 8 System Layout... 9 SYSTEM LAYOUT - PORTRAIT SYSTEM LAYOUT - LANDSCAPE Pre-Job Layout Preparations... 10 Wall Mounts... 11 Horizontal Leg... 12 Angle Adapter... 13 Angled Frame To L-Foot... 14 Angled Frame To Adapter... 15 Cross Connectors... 16 Bracing... 17 Cross Rails... 18 Fixed Rail Connector... 19 Flexible Rail Connector... 20 Microinverter... 21 End Clamp & First Module... 22 Mid Clamp & Module... 23 Cutting Access Rail... 24 End Cap... 25 Grounding Lug... 26 Jumper Wire at Flexible Rail Connector Locations... 27 Wire Management Clip... 28 Appendix... 29 TABLE OF CONTENTS Table of Contents 3 / 35
PRE-JOB LAYOUT PREPARATIONS COMPLETE A SITE SURVEY 1. Obtain a set of roof plans or draw your own. 2. Verify that all dimensions are correct. 3. Note locations of roof penetrations (chimneys, vents, etc.) 4. Note the roof construction materials and locate framing member locations, paying attention to the spacing of the framing members. 5. Assess objects creating shading concerns DETERMINE THE SOLAR LAYOUT 1. It is recommended that your design be approved by a local building authority before beginning installation. Typically the rail span between supporting roof anchors is the most important design consideration. A solar checklist form and web resources are available at http://trasnowandsun.com/solar-mounting/solarmounting-checklist/. Solar checklist information must be provided along with jobsite information (preferably a roof plan) in order to provide the free solar array layout. For more details contact TRA Snow and Sun. 2. The solar layout should be designed with the following factors in mind that affect the structural design of the solar array: Windspeed Building height Snow load Exposure category Importance factor Roof slope/pitch 3. Other factors to be considered: Sun exposure Objects causing shading Proximity to inverters/electrical panels String capacities, etc. 4. Some local jurisdictions fire codes require walkways or edge clearances. Pre-Job Layout Preparations 4 / 35
COMPONENTS Components 5 / 35
ROOF ATTACHMENTS COMPONENTS L-FOOT 77000502 L-FOOT 77000502A MODULE CLAMPS RAIL CONNECTORS MID CLAMP ASSEMBLY 15101XXX END CLAMP ASSEMBLY 15102XXX CROSS CONNECTOR 74011001 FIXED FLEX CONNECTOR 740XXXXX THIN FILM MID CLAMP ASSEMBLY 72203XXX THIN FILM END CLAMP ASSEMBLY 72203XXX Components 6 / 35
ACCESSORIES RAIL END CAP 18000335 WIRE MANAGEMENT CLIP 72215XXX SOLAR RAIL PLUS 7403XXXX INSTALLATION COMPONENTS MANUALS WEEB LUG 8.0 WEEB-LUG WEEB-SMC 2 WEEB-SMC FASTENERS M8 FLANGE LOCK NUT 15100041 SLIDING BLOCK 151100025 SDS SCREW SDSS101 SOCKET HEAD CAP SCREW *Actual Size Components 7 / 35
SYSTEM COMPONENTS 5 SYSTEM COMPONENTS 1 10 7 3 4 9 11 6 8 12 14 2 13 15 1 SOLAR RAIL PLUS: Supports PV modules and accessories. Available in lengths up to 20 6. Extruded aluminum. Available in mill finish or black anodized. 2 CROSS CONNECTOR: Supports cross braced mounting systems. Aluminum mill finish or black anodized. 3 FLEXIBLE RAIL CONNECTOR: Joins and aligns rail sections allowing for expansion due to natural temperature variation. Installed every 50 of Solar Rail Plus. Mill finish aluminum. (Non-bonded) 4 FIXED RAIL CONNECTOR: Joins, aligns, and electrically bonds rail sections into single length of rail. Available in mill finish or black anodized. 5 END CLAMP ASSEMBLY: Includes End Clamp, Solar Grounding Clip, and M8 Socket Head Cap Screw 6 MID CLAMP ASSEMBLY: Includes Mid Clamp, Solar Grounding Clip, M8 Socket Head Cap Screw 7 END CLAMP: Pre-assembled End Clamp with Solar Grounding Clip (SGC) provides module to rail bond. End Clamp available in mill finish and black anodized. 8 MID CLAMP: Pre-assembled Mid Clamp with Solar Grounding Clip (SGC) provides module to module and module to rail bond. Mid Clamp available in mill finish and black anodized. 9 ROLL IN BLOCK: Easily clips into place in the top channel of the Solar Rail Plusl for easy Mid/End Clamp placement. Provides electrical bond between Mid Clamp or End Clamp to the rail. Mill finish aluminum. 10 L-FOOT: Secures rails to wall. Mill finish aluminum. 11 M8 SOCKET HEAD CAP SCREW: Use when securing components to the Solar Rail Plus in conjunction with the Sliding Block or Solar Grounding Clip. Stainless Steel. 12 END CAPS: Provide a clean, finished appearance on ends of Solar Rail Plus concealing any rough edges. Polypropylene End Cap available in grey or black. 13 GROUNDING LUG (WEEB LUG 8.0): Used to ground the Solar Rail Plus to a copper ground wire. Includes a stainless steel washer and a tin-plated copper lug. 14 SLIDING BLOCK: Provides threaded connection point to Solar Rail Plus. Rolls and slides into place in channels of Solar Rail Plus. Mill finish aluminum. 15 ANGLE ADAPTER: Used to connect two pieces of rail at an angle to join the tilted portion of the structure. System Components 8 / 35
AWNING LANDSCAPE (OPTION A) AWNING PORTRAIT (OPTION B) ATTACHMENT INSTALLATION COMPONENTS MANUALS Attachment Components 9 / 35
MODULE COMPATIBILITY INSTALLATION MANUALS MODULE COMPATIBILITY Height Varies or SOLAR RAIL PLUS The heights of the End Clamp Assembly and Mid Clamp Assembly varies and are dependant on the solar module frame thickness. TRA Snow and Sun can customize End Clamps to fit any solar module. Module Compatibility 10 / 35
TRA Snow and Sun will provide an engineered layout for all Awning Mount Systems we design. An engineered plan will specify the spacing requirements per the project design criteria. As a standard, we design the Solar Rail Plus to be installed parallel or perpendicular to the rafters/trusses. Custom designs are available. Supporting wall attachments are required to be spaced, depending on local building requirements. The installer should check with the local building department to make sure the project complies with the specific code requirements for their locality. Customer is required to provide and verify that all design criteria is correct. AWNING LANDSCAPE (OPTION A) SYSTEM LAYOUT - LANDSCAPE TRA Snow and Sun s Landscape layout is installed with the mounting rails perpendicular to the wall. All wall attachments are mounted so flashing can be added to create a waterproof seal. Supporting wall attachments are required to be spaced, using either cross connectors or cross rails depending on local building requirements. The installer should check with the local building department to make sure the project complies with the specific code requirements for their locality. SYSTEM LAYOUT AWNING PORTRAIT (OPTION B) SYSTEM LAYOUT - PORTRAIT TRA Snow and Sun s portrait layout is installed with the mounting rails parallel to the wall. All wall attachments are mounted so flashing can be added to create a waterproof seal. Supporting roof attachments are required to be spaced, using either cross connectors or cross rails depending on local building requirements. The installer should check with the local building department to make sure the project complies with the specific code requirements for their locality. NOTES: Mid Clamp Assembly requires a ¾ inch gap between modules. TRA recommends 2 of Solar Rail Plus protruding at the ends of any string of panels for End Clamps and/or Grounding Lugs. Maximum rail span cannot exceed 6. The distance between roof attachments should be 6 apart or less. System Layout 11 / 35
PRE-JOB LAYOUT PREPARATIONS COMPLETE A SITE SURVEY 1. Obtain a set of roof plans or draw your own. 2. Verify that all dimensions are correct. 3. Note locations of roof penetrations (chimneys, vents, etc.) 4. Note the roof construction materials and locate framing member locations, paying attention to the spacing of the framing members. 5. Assess objects creating shading concerns DETERMINE THE SOLAR LAYOUT 1. It is recommended that your design be approved by a local building authority before beginning installation. Typically the rail span between supporting roof anchors is the most important design consideration. A solar checklist form and web resources are available at http://trasnowandsun.com/solar-mounting/solarmounting-checklist/. Solar checklist information must be provided along with jobsite information (preferably a roof plan) in order to provide the free solar array layout. For more details contact TRA Snow and Sun. 2. The solar layout should be designed with the following factors in mind that affect the structural design of the solar array: Windspeed Building height Snow load Exposure category Importance factor Roof slope/pitch 3. Other factors to be considered: Sun exposure Objects causing shading Proximity to inverters/electrical panels String capacities, etc. 4. Some local jurisdictions fire codes require walkways or edge clearances. Pre-Job Layout Preparations 12 / 35
Brick Step 1 WALL MOUNTS The Awning Solar Mounting Frame can be mounted on any wall type (concrete, frames, metal, brick, etc.). The fasteners are to be determined by the custpmer based on the material strength of the wall or wall framing material. MARK FRAME LOCATIONS TO PREPARE THE ROOF 1. Determine the location for the Frames on the vertical wall structure. (Refer to information gathered in the site survey and module manufacturer recommendations.) WALL MOUNTS 2. Mark the location using a chalk line to ensure a plum installation. Mark a horizontal line in the locations the Awning Frame is to be installed. 3. Layout Awning Frames at chalk line locations. 4. Mount the L-Base Brackets to the wall with customer determined fastener. 5. Spacing & locations is dtermined by TRA s Engineered Layout. Concrete NOTES: Spacing varies based on the size of the solar panel, wall framing spacing and the desired mounting angle of the system. Please refer to system drawings provided by TRA Snow and Sun for the correct spacing for your wall mounts. Studs Wall Mounts 13 / 35
Step 2 HORIZONTAL LEG HORIZONTAL LEG 1. Attach the Rails to the roof mount by first seating the Sliding Block into the Rail side channel in proximity to the mounting location by rolling it into the channel. 2. Set the rail into position with side channel flush against the uphill face of the attachment. Adjust Sliding Blocks by sliding them into alignment with the slotted hole. (If a Flexible Connector is needed insert it before adding additional rails.) 3. Insert the Socket Head Cap Screw through the roof attachment into the Sliding Block that is positioned inside the side channel of the Rail and torque to 12 ft-lbs. NOTES: The L-Foot requres a M8 X 16mm Socket Head Cap Screw. Rail is installed with the top channel facing the ground. Make sure rail is horizontal. Horizontal Leg 14 / 35
Step 3 ANGLE ADAPTER FRAME LAYOUT 1. Attach the Angle Adapter to the Solar Rail Plus by first setting the Sliding Block into the Solar Rail Plus side channel in proximity to the mounting location by rolling it into the channel. ANGLE ADAPTER 2. Hand tighten M8 x 16mm Socket Head Cap Screw until after step 6 is completed. Angle Adapter 15 / 35
ANGLED FRAME TO L-FOOT Step 4 ANGLED FRAME TO L-FOOT 1. Attach the Rails to the roof mount by first seating the Sliding Block into the Rail side channel in proximity to the mounting location by rolling it into the channel. 2. Set the rail into position with side channel flush against the uphill face of the attachment. Adjust Sliding Blocks by sliding them into alignment with the slotted hole. (If a Flexible Connector is needed insert it before adding additional rails.) 3. Insert the Socket Head Cap Screw through the roof attachment into the Sliding Block that is positioned inside the side channel of the Rail and torque to 12 ft-lbs. NOTES: The L-Foot requres a M8 X 16mm Socket Head Cap Screw. Rail is installed with the top channel facing the ground. Make sure rail is horizontal. Angled Frame To L-Foot 16 / 35
Step 5 ANGLED FRAME TO ADAPTER 1. Attach the Angle Adapter to the Solar Rail Plus by first setting the Sliding Block into the Solar Rail Plus side channel in proximity to the mounting location by rolling it into the channel. 2. Torque M8 x 20mm Socket Head Cap Screw to 12 ft-lbs. ANGLED INSTALLATION FRAME TO MANUALS ADAPTER 3. Torque all Socket Head Cap Screws from STEPS 4-5 to 12 ft.-lbs. Angled Frame To Adapter 17 / 35
Step 6 CROSS CONNECTORS CROSS CONNECTORS 1. If (1) one column of frames the back bracing needs to be crossed. Attach Back Brace by using (5) M8 x 16mm Socket Head Cap Screw and (5) M8 flange lock nuts. 2. If multiple columns of frames the back bracing can be staggered. Attach Back Brace by using (2) M8 x 16mm Socket Head Cap Screw and (2) M8 flange lock nut. Where the Back Bracings overlap (1) M8 x 16mm Socket Head Screw and (1) M8 flange lock nut will not be needed. 3. Torque all connections to 15 ft. -lbs. 4. Repeat Steps 1-2 for all Backing using the engineered layout drawing as a guide. Cross Connectors 18 / 35
ZIGZAG PATTERN - OPTION 1 Step 7 BRACING 1. If (1) one column of frames the back bracing needs to be crossed. Attach Back Brace by using (5) M8 x 16mm Socket Head Cap Screw and (5) M8 flange lock nuts. 2. If multiple columns of frames the back bracing can be staggered. Attach Back Brace by using (2) M8 x 16mm Socket Head Cap Screw and (2) M8 flange lock nut. Where the Back Bracings overlap (1) M8 x 16mm Socket Head Screw and (1) M8 flange lock nut will not be needed. INSTALLATION BRACING MANUALS 3. Torque all connections to 15 ft. -lbs. 4. Repeat Steps 1-2 for all Backing using the engineered layout drawing as a guide. CROSS PATTERN - OPTION 2 NOTES: The braces should be between two panels to tie the system together, not under a single panel. Bracing 19 / 35
Step 8 CROSS RAILS - PORTAIT OPTION B For landscape module layouts using cross rails, add additional rails perpendicular to previously mounted rails to support modules. CROSS RAILS 1. Attach the Cross Connector to the Solar Rail Plus by first seating the Sliding Block into the Solar Rail Plus top channel in proximity to the mounting location by rolling it into the channel. Torque M8 X 16 Socket Head Cap Screw to 12 ft-lbs. (This will be done on the horizontal Solar Rail Plus previously installed.) 2. Attach the Cross Connector to the Solar Rail Plus by first seating the Sliding Block into the Solar Rail Plus side channel in proximity to the mounting location by rolling it into the channel. 3. Set the rail into position with side channel flush against the vertical face of the Cross Connector and Weeb-SMC-2. Adjust Sliding Blocks by sliding them into alignment with the Cross Connector mounting hole. 4. Insert the M8 X 16 Socket Head Cap Screw through the Cross Connector and Weeb-SMC-2 then into the Sliding Block that is positioned inside the side channel of the Solar Rail Plus and torque to 12 ftlbs. NOTES: A Weeb-SMC-2 is required for connections between the Cross Connector and the Solar Rail Plus. Cross Connector is not symetrical. A M8X16 Socket Head Cap Screw is used on the thin side and an M8 X 20 Socket Head Cap Screw is used on the larger side. Cross Rails 20 / 35
Step 9 FIXED RAIL CONNECTOR - PORTAIT OPTION B 1. Align the two (2) rail ends next to each other and snap the Fixed Rail Connector in place and fasten with (2) self tapping screws into the side of the Solar Rail Plus. 2. Torque all connections to 12 ft. -lbs. FIXED RAIL CONNECTOR Fixed Rail Connector 21 / 35
FLEXIBLE RAIL CONNECTOR Step 10 FLEXIBLE RAIL CONNECTOR - OPTION B 1. Align the two (2) rail ends next to each other and snap the Fixed Rail Connector in place and fasten with (1) self tapping screws into the side of the Solar Rail Plus. 2. Torque all connections to 12 ft. -lbs. 3. Do not push rails tight together. Leave a 2 gap to allow for expansion. Flexible Rail Connector 22 / 35
Step 11 MICROINVERTER One microinverter must be installed for each module. 1. Insert Sliding Block into the top channel of the Solar Rail Plus. 2. Using an M8 X 10mm Socket Head Cap Screw attach the microinverter. INSTALLATION MICROINVERTER MANUALS 3. Torque to 12 ft-lbs. 4. Repeat for each microinverter. NOTES: For additional options to mount microinverters, contact TRA Snow and Sun. Inverter bonding was not tested by UL. Microinverter 23 / 35
END CLAMP AND FIRST MODULE STEP 12 END CLAMP AND FIRST MODULE End Clamps are used on the first and last modules of a string or array to secure the edge of the module to the Solar Rail Plus. For easy installation the End Clamp Assembly is installed as a pre-assembled component with a Socket Head Cap Screw fastened through the End Clamp and into the Roll In Block. 1. Roll the End Clamp Assembly into the top channel on the Solar Rail Plus and slide it into place. 2. Slide the module into place and loosely secure the End Clamp Assembly. 3. Repeat at the ends of each rail. 4. Align modules into place then tighten the End Clamp Assembly and torque to 15 ft. -lbs. NOTES: The height of the End Clamp Assembly vary and are dependent on the solar module frame thickness. (Works for both regular and Glass Clamps) End Clamp and First Module 24 / 35
INSTALLATION MANUALS STEP 13 MID CLAMP AND MODULE Mid Clamps are used to secure two modules to the Solar Rail Plus. For easy installation the End Clamp Assembly is installed as a pre-assembled component with a Socket Head Cap Screw fastened through the End Clamp and into the Roll In Block. 1. Roll the Mid Clamp Assembly into the top channel on the Solar Rail Plus and slide it into place. 2. Slide the module into place and loosely secure the Mid Clamp Assembly. MID CLAMP AND MODULE 3. Repeat for each subsequent module. 4. Align modules into place then tighten the Mid Clamp Assembly and torque to 15 ft. -lbs. (Works for both regular and Glass Clamps) NOTES: The height of the End Clamp Assembly vary and are dependent on the solar module frame thickness. Mid Clamp and Module 25 / 35
STEP 14 CUTTING ACCESS RAIL CUTTING ACCESS RAIL 1. If the Solar Rail Plus extends out beyond the required distance (2 ) from the module the excess may be cut off. Cutting Access Rail 26 / 35
STEP 15 END CAP 1. To install the End Cap, align the pegs of the End Cap with the corresponding locations in the rail profile and press in. The End Cap may also be gently tapped with a hammer or similar instrument. It must be completely seated into the end of the Solar Rail Plus to ensure effectiveness. END CAP Continue to STEP 16 on page 26 - GROUNDING LUG. End Cap 27 / 35
STEP 16 GROUNDING LUG A Grounding Lug must be installed at the end of each run of modules on the end of the Solar Rail Plus. GROUNDING LUG 1. Insert Sliding Block into the top channel of the Solar Rail Plus. 2. Using an M8 X 16mm Socket Head Cap Screw attach the Grounding Lug and Lug Washer. 3. Torque to 12 ft. -lbs. 4. Repeat for each end of rail. NOTES: Grounding Lug must be attached at 60 in-lbs to 6-14 AWG solid/strand copper wire. Grounding Lug 28 / 35
STEP 17 JUMPER WIRE AT FLEXIBLE RAIL CONNECTOR LOCATIONS For Solar Rail Plus lengths exceeding 50 a Flexible Rail Connector is required, Grounding Lugs must be installed on both sides and a jumper wire used to tie the two (2) Solar Rail Plus runs together. 1. Slide Sliding Blocks into side channel of both rails near the Flexible Rail Connector (not always needed). 2. Align and install (2) Grounding Lugs. JUMPER WIRE AT FLEXIBLE RAIL CONNECTOR 3. Attach the (10) gauge solid copper wire to both lugs. 4. Droop the wire to allow for expansion. NOTES: Grounding Lug must be attached at 60 in-lbs to 6-14 AWG solid/strand copper wire. Jumper Wire At Flexible Rail Connector 29 / 35
STEP 18 WIRE MANAGEMENT CLIP WIRE MANAGEMENT CLIP 1. To install the Wire Management Clip, align the bottom U on rail wire management channel and clip to channel of Solar Rail Plus and snap into place. 2. Continue placing Wire Management clip where is necessary. Wire Management Clip 30 / 35
APPENDIX MAINTENANCE Perform a visual inspection annually to ensure there is no damage to mounting hardware. Complete inspection bi-annually to ensure there are no loose fasteners, connection points, to ensure proper grounding and that the system will withstand any inclement weather. All components to be single use only for bonding. MODULES TESTED WITH THIS RACKING SYSTEM Solar World: SunModule Plus SW 270 mono, SunModule Plus SW 275 mono, SunModule Plus SW 280 mono APPENDIX Canadian Solar: CS6P-250w, CS6P-255w, CS6P-260w, CS6X-300w, CS6X-305w, CS6X-310w Sunpreme Modules: Maxima GxB 300 SL Bifacial Module Note: Other modules are compatible with the Flush Mount System. To have UL Certification with the Flush Mount System the listed modules are required. FIRE RATING FUSE RATING This system has been tested to a max fuse rating of 25 Amps. MISSION STATEMENT TRA Snow and Sun s Mission is to offer the highest quality snow retention, solar mounting systems, flexible roof flashing and ventilation products made from superior materials that provide the ultimate in protection, durability and dependability. We strive daily to provide customized service, exceptional engineering, superior manufacturing, and resourceful solutions for each customer, focusing on the unique requirements of each project. Our team is united, innovative and dedicated. Each employee pursues excellence in each company endeavor and realizes that maintaining the good reputation that took decades to establish depends on them. We are not content to simply be successful, but strive to set new and higher standards in all that we do. Appendix 31 / 35
At TRA Snow and Sun we engineer and layout each project upon request free of charge. Just give us the project details and we will give you the rail spans, max loads on components, wind parameters, solar panel geometry, force per foot on rail and panels, a schematic of the module field, the wind speed, shipping weight, and project details. CONTACT US TRA SNOW AND SUN 800-606-8980 info@trasnowandsun.com