PAGE-1 UPDATED 3-6-2015 REV.1 BLACK WIDOW COMPOSITE Detailed installation manual
PAGE-2 UPDATED 3-6-2015 SpiderRax, Inc. REVISION PAGE Installation Manual For BWC-S, BWC-B,BWC-F DATE PAGES REASON OLD LEVEL NEW LEVEL
PAGE-3 UPDATED 3-6-2015 INDEX Page 1. Cover page Page 2....Revision page Page 3...Index Page 4...Design Specifications Page 5......Introduction Page 6 Tool list & step overview Page 7-12..Assembly Page 13-16.. Layout Procedures Page 17... Cutting composite shingle Page 18....Attachment Page 19..Flashing Page 20-21.. Panel Installation Page 22-26....Grounding Page 27.... Inspection & clean up
PAGE-4 UPDATED 3-6-2015 BLACK WIDOW COMPOSITE Design Specifications Design Load: 30Psf Torque 20 ft-lbs. Fuse rating: 20A Max number of modules and connections per ground lug: 10 Frame thickness: (35mm-40mm)( 1.377-1.574 )
PAGE-5 UPDATED 3-6-2015 SPIDER RAX BLACK WIDOW COMPOSITE INSTALLATION MANUAL APPLICATION: COMPOSITE SHINGLE ROOF The BLACK WIDOW COMPOSITE pv mounting system is designed to reduce material cost and pre-installation requirements. The BLACK WIDOW mounting system is sub-assembled upon delivery. This system requires no rails and no studs which dramatically decreases shipping and installation cost. WARNING All SPIDER RAX products are designed and tested to withstand all regional specifications when installed correctly. Failure to install SPIDER RAX products correctly may decrease performance of the installation. To be used only in combination with modules that include the Black Widow rack system in their installation manual. SAFETY All local safety requirements should be followed when installing all SPIDER RAX products. All tools, equipment, and roofing materials should be located safely and secured at all times during installation to avoid falling object hazards. All tools/equipment should be inspected prior to installation to ensure proper operational use. This installation guide is intended for professional pv installers with a background in construction principles.
PAGE-6 UPDATED 3-6-2015 TOOL LIST Cordless impact wrench with ¼ adapter fitting 1 / 4 socket 9 / 16 deep socket Utility knife Tape measure Lumber crayon Silicon gun & outdoor silicone Chalk line & string line OVERVIEW 1) Black Widow Composite mount assembly 2) Marking panel & footing layout 3) Cut composite shingle 4) Attachment of Black Widow Composite mounting system 5) Install flashing 6) Final positioning & Panel installation 7) Grounding 8) Quality inspection & clean up
PAGE-7 UPDATED 3-6-2015 Step 1: Black Widow Composite assembly Parts required for step 1 1. One base plate. P/N FM-C2007S (Aluminum) 2. One s-hook. P/N BW-C3024 (Aluminum) 3. One rail. P/N TR-C3022S (Aluminum)
PAGE-8 UPDATED 3-6-2015 4. One Bottom clamp. P/N MC-C3011S (Aluminum) 5. One top clamp. P/N TC-C2002S (Aluminum) 6. One 3/8 x 3 hex bolt. P/N FS-C38300S (Stainless steel) 7. One 3/8 x 1 hex bolt P/N FS-C38100S (Stainless steel)
PAGE-9 UPDATED 3-6-2015 8. One 3/8 x ¾ hex bolt. P/N FS-C38075S (Stainless steel) 9. Three 3/8 serrated flange nut. P/N FN-F38S (Stainless steel) 10. Three 3/8 star washers. P/N FW-S38S (Stainless steel) 11. Two No. 4 x 3/16 screw P/N FS-M436S (sub-assembled) (Stainless steel)
PAGE-10 UPDATED 3-6-2015 1.1 Select one base plate. Part 1 1.2 Select one S-Hook and position the S-Hook over the base plates track. Select one 3/8 serrated flange nut and place it in the center of the base plate s nut channel. Select one 3/8 x 3/4 hex bolt fitted with a star washer. Place the bolt through the S-Hook fitting and thread the bolt until hand tight. Once in place the S-Hook will slide along the track for lateral adjustment. Part 1 Part 8 Part 10 Part 9 Part 2
PAGE-11 UPDATED 3-6-2015 1.3 Select one rail and insert a one serrated flange nut in the bottom channel on the grooved side of the rail. Select one 3/8 star washer and one 3/8 x 1 hex bolt and join the two pieces together. Place the hex bolt through the slot located on the top of the S-Hook and thread the bolt on the flange nut to join the s-hook and the solar rail. Part 10 Part 3 Part 7 Part 8,9,10 Part 9 Part 2 Part 1
PAGE-12 UPDATED 3-6-2015 1.4 Once the rail is attached to the s-hook, select one bottom clamp and position it on top of the rail. Next select one top clamp and place it in the top mount channel located on the bottom clamp. Select one flange nut and insert it in the top channel of the rail. Select one 3/8 x 3 hex bolt and one 3/8 star washer. Fit the hex bolt with the star washer and insert the bolt through the top and bottom clamp and thread the bolt on the serrated flange nut located in the rail. Part 6 Part 10 Part 5 Part 4 Part 9
PAGE-13 UPDATED 3-6-2015 STEP 2: Marking panel and footing layout Note: Before applying mounting attachments, drawing a system layout is highly recommended. For our demonstration of the Black Widow Composite installation we will be using a simulation roof. Fire lanes are not included during this example. If required by regional specifications, account for fire lane and position your layout accordingly. 2.1 Start at the left/top of the layout and mark the top/left corner of the first panel in the top row. Use a lumber crayon for all marks during step 2. 2.2 Move to the left/bottom of the layout and mark the bottom/left corner of the first panel in that row.
PAGE-14 UPDATED 3-6-2015 2.3 Use a calculator to multiply panel width by the amount of panels going to be used in the row account for a ½ for the top clamps. If your row consist of two panels that are 39.5 mark at 80 at the end of the row. 2.4 Move to the right side of the layout and repeat steps at the distance taken from step 2.3 2.5 Move to the top/left side of the layout and mark the first footing position for the first panel in the top row. The footing mark should be made 6 down from the top edge of the panel mark and in line with the left vertical panel mark.
PAGE-15 UPDATED 3-6-2015 2.6 Move to the left/bottom of the layout and mark the first footing position for the first panel in the bottom row. The footing mark should be made 6 up from the bottom edge of panel mark and in line with the left vertical panel mark. 2.7 Chalk line between the top and bottom footing mark and then mark all footing positions on the left side of the layout. Keep in mind that the edge of the footing mark should be 6 from the edge of the panel. 2.8 Move to the right side of the array and repeat step 2.7
PAGE-16 UPDATED 3-6-2015 2.9 Make all horizontal footing marks in between the left and right side of the layout. 2.10 Chalk line all vertical and horizontal marks. Upon completion of this step you should have a grid pattern on the roof. This grid will give you all footing positions for the layout. Landscape Layout In the event your layout requires a landscape orientation, make adjustments for steps 2.1 2.10 to account for the change in panel dimensions. Position all mounts on the short side of your module and follow all procedure s listed above. Note: When attaching to the short side of the panel Spider-Rax Red Widow mounts must be placed within 6 from the panels
PAGE-17 UPDATED 3-6-2015 STEP 3: Cut composite shingle 3.1 Center the base plate on the footing mark and trace base plate at the bottom edge of the composite shingle. 3.2 Use a utility knife to cut out the marked portion of the composite shingle. This will allow the flashing to set in the proper position. 3.3 When completed the trimmed section of composite shingle should appear as shown.
PAGE-18 UPDATED 3-6-2015 STEP 4: Attachment of Black Widow Composite mount 4.1 Remove outer film from the adhesive water tight layer located on the base plate. 4.2 Configure the Black Widow Composite mount in the removed section of the composite. 4.3 Use a cordless impact wrench fitted with a 1 / 4 socket to secure the mount to the roof deck using * (10 x 1 ¼ ) screws included with the Black Widow mount. Torque all screws to 14 ft-lbs. Note: * California: 5 Screws * Florida: 8 Screws * Hawaii: 8 Screws * Texas: 6 Screws
PAGE-19 UPDATED 3-6-2015 STEP 5: Install flashing 5.1 Position the flashing above the base plate with the three outer edges of the flashing under the layer of composite shingle. 5.2 Ensure that the layer of composite shingle sets flush with the raised portion of the flashing. CAUTION: Flashings may have sharp edges. Wearing safety gloves is recommended while handling flashings.
PAGE-20 UPDATED 3-6-2015 Step 6: Final positioning & module installation 6.1 Connect a string line between the top/bottom mounts and adjust all mounts in line with the string. 6.2 Adjust all mounts to the desired height using the adjustment bolt located on the front side of the s-hook. 6.3 Starting at the bottom/left of the layout, place one panel between the Black Widow Composite top clamp and bottom clamp.
PAGE-21 UPDATED 3-6-2015 6.4 Adjust the panels over hang to no more than 12 from center of the mounts top clamp bolt and tighten the top camp to 20 ft-lbs. using a torque wrench or impact wrench fitted with a 9/16 deep socket to secure panel in place. 6.5 Repeat all previous procedures, completing one row of the array at a time until all panels are installed and secured. Adjust accordingly to ensure a square and level finished product.
PAGE-22 UPDATED 3-6-2015 Parts required for ground lug assembly STEP 7: Grounding 1. One ILSCO, Ground Clamp Lug, GBL -1/0 P/N ILSCO 2. One grounding set screw P/N FS-T14050 3. One ¼ x ¾ hex bolt P/N FS-C 14075S (Stainless) 4. One ¼ hex nut P/N FN-H14S (Stainless)
PAGE-23 UPDATED 3-6-2015 5. Two ¼ star washers P/N FW-S14S (Stainless) NOTE: For a system using a non-integral module or panel, the assembly must be mounted over a fire resistant roof covering rated for the application. Any slope less than 5 in/ft (127 mm/305 mm) is required to maintain a fire class rating.
PAGE-24 UPDATED 3-6-2015 Assembly & Attachment 8.1 Select one ground lug and insert one ¼ x ¾ hex bolt into the ground lug on the flat portion of the lug. Part 1 Part 3 8.2 Once the bolt is through the lug insert a star washer on the bolt. Part 1,2 Part 5
PAGE-25 UPDATED 3-6-2015 8.3 Select one Grounding set screw. Thread the set screw in the ground lug with the slotted portion of the set screw facing out. Part 2 8.4 Part 1, 3, 5 Place the ground lug bolt through the grounding hole on the s-hook. Part 1, 2, 3, 5
PAGE-26 UPDATED 3-6-2015 8.5 Select the second star washer and place it on the hex bolt. Select one ¼ hex nut and thread the nut clockwise on the bolt until the nut is hand tight. Part 4 Part 1, 2, 3, 5 Part 5 8.6 Use a torque wrench and tighten the ¼ hex nut to 12 ft-lbs. This will bond the lug to the footing. Spider-Rax Ground lugs are designed to accept #4, #6, #8, and, #10 bare copper and/or stranded copper. The Black Widow incorporates an integrated ground. This is achieved through abrasion. Only one ground lug and ground wire connection is needed for every 10 modules. A separate ground must be attached after the span of 10 panels. NOTE: Check with local regulations on the minimal size conductor to be used. Part 1, 2, 3, 4, 5
PAGE-27 UPDATED 3-6-2015 STEP 9: QUALITY INSPECTION & CLEAN UP 9.1 Once all panels are installed and roof tiles are replaced, apply a firm pull test to ensure all attachments are secured firmly to the roof of the structure. NOTE: It is required to use four Black Widow Composite mounts for every one module. 9.2 Account for all tools and jobsite related material and clean area as necessary. This concludes the installation process of the SPIDER-RAX, Black Widow Composite mounting system. Questions or concerns can be answered at 1-844-773-7729 Spiderrax.com info@spiderrax.com