Assembly Instructions for SunLink RMS

Transcription

Assembly Instructions for
SunLink RMS
TABLE OF CONTENTS
Notices and Safety Precautions
Pages 1-2
Component and Tool Quick Reference
Pages 3-4
Substrate Installation
Page 5
Panel Assembly
Pages 6-7
Panel Installation
Page 8
Lateral Link Installation
Page 9
Tilt Access Feature
Page 10
Ballast Pan Installation
Pages 13
Flashable Post Anchor Installation
Page 14
Appendix A – Field Drilling
Pages 15-16
Sample Elevation View -- 10° System
(Refer to pages 3-4 for more detail.)
Clamp Block
PV Module
Pivot Block
Anchor Block
Spar
Long Link
End Row Tilt Bracket
(Smaller than Tilt Bracket)
Tilt Bracket
1010 B Street, Suite 4100 – San Rafael, CA 94901
415-925-9650 – www.sunlink.com
End Row Tilt Bracket
(Smaller than Tilt Bracket)
1
Read this document before beginning installation work. Plan for safe practice during any installation activity with respect to
hazards from tripping, falling, lifting, repetitive stress, and any overhead or electrical hazards. When working close to building roof
edges, consider protection options that reduce worker exposure to fall hazards. Refer to OSHA Sub-Chapter 7, Group 1, Article 2.
The SunLink® RMS is made from aluminum alloy, fastened together with stainless steel assembly hardware. Aluminum alloy
components are manufactured per ASTM B209 and ASTM B221. 5052-H32 is used for sheetmetal components, and tempered 6000
series alloys are used for extruded components. In the forms used in SunLink, these materials are considered to be non-toxic. Metal
components often have sharp edges. Handle carefully! Wearing gloves is good practice. Also, Be careful of pinch hazards, especially
when lowering panels onto Tilt Brackets.
This document is not prescriptive regarding safety and does not purport to address all the safety concerns that may arise with its use.
Contractors should become familiar with all applicable safety, health and regulatory requirements before beginning work.
Electrical safety notice – Any time a SunLink panel contains two or more electrically interconnected modules, a shock hazard is
present. SunLink is a mechanical system and contains no “live” parts. Mechanical installers and electricians should coordinate in
order to ensure that all personnel are aware of electrical hazards.
Precedence – The SunLink RMS positions and secures photovoltaic modules. DC “stringing” and interconnection of the modules
requires placement of conduit, conduit fittings and combiner boxes. Nothing in this document is intended to limit the allocation of
rooftop space or to control crafts with respect to work precedence and coordination.
Build rate – Estimated mechanical installation rate (modules per day) for an array consisting of commercial-class modules installed
with a SunLink RMS and assuming a well-equipped four-person crew is on the roof and working 7.5 hours / day with full task
interchangeability: > 120 modules / day.
As-built documentation process – On-roof use and mark-up of this document and the drawings and printed matter referred to in
this document is good practice. Mark up and annotate the drawings on a regular basis, noting completions, exceptions, dimensional
inconsistencies, etc.
Layout: When installing SunLink RMS, unless otherwise noted on the layout drawings, the recommended practice is to allow for up
to 4 inches of array movement on the roof. Movements can be caused by thermal effects, roof vibrations, earthquakes, and wind
storms. It is also recommended to install a service loop for all electrical wiring entering or leaving the array, and for any wiring that
crosses between two unconnected structural components within the array.
Field modifications – Unauthorized field modification of SunLink components or assemblies may affect SunLink warranty coverage.
Provide marked up drawings for SunLink’s review, comment and approval prior to attempting any field modifications.
Work arounds – Workers laying out or installing arrays on rooftops 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
noted on working drawings. When a work around affects the location of two or more modules at once, the supervisor should be
advised and the work around should be evaluated and then completed in a manner that ensures that the remainder of the array is
not affected.
Fire-safe roof – The SunLink RMS is to be mounted over a fire resistant roof covering rated for the application. The SunLink RMS is
not meant for sloped roofs where the slope is greater than 1 ½”:12” (7° or 12%).
1
Fit-up – SunLink is a designed-fit system and is assembled using fasteners and assembly bolt sets. Matching hole locations are
developed to ensure long-term reserve assembly strength and life cycle reliability. Since undulation and slope is required to ensure
roof drainage, SunLink incorporates features that allow the array to follow the roof contour. Line-up for final bolted connection
typically involves light “bucking in” during assembly. A drift pin is a useful tool with which to align holes for cross-bolting.
Roof life and care – The service life of any roof is contingent upon care for the roof especially during equipment installation on a
roof. Avoid concentrated loads on the roof. Never drag SunLink components into place. Instead, elevate the component, and then
move it manually or with a cart. Locate it and then place it “on spot.” To ensure roofing system warranty continuation, work with
roofing system installation contractors to ensure roofing system – array compatibility.
WARNING! Single-ply roofs are susceptible to damage. Avoid accumulation of metal fines that result from drilling or sawing metal
components. Metal fines embedded in the soles of shoes can damage single-ply roofs.
Fasteners – All required fasteners are furnished with the SunLink RMS. All fasteners are 18Cr-8Ni stainless steel. For any assembly,
finish initial bolted assembly to finger tight. Button-head cap screws (BHCS) are precision, low-profile fasteners. Use of air-powered
tools that do not incorporate means to limit applied torque may damage the head of these fasteners and is not recommended.
Final inspection – Visually inspect the assembled SunLink RMS arrays, roof-mounted or ground supported. The suggested process
consists of a row-by-row walk-through and then a perimeter walk-around, after mechanical assembly, before electrical completion.
Report any distortion in the assembly to SunLink. Array substrate supports should be in full contact with the roof or the ground. Any
indication of uneven distribution of weight should be evaluated and corrected before continuing with electrical finishing.
Tilt Access™ best practices – Tilt Access is a unique feature to the SunLink RMS that allows you to flip the panels up and out of the
way. During installation do not leave panels unattended in the tilt up position. Do not place panels in locked tilt up position if winds
exceed 15mph.
Temporary ballast -- At the end of every work day, ensure all components are securely attached. Temporary ballast (e.g. sandbags)
may be required to secure the system to the roof during the installation process to prevent movement or damage due to wind.
Installation Guide Addendums: The following addendums are available from your SunLink project manager: Deep Links, Enphase
Inverters, Inrigger Assembly, Outrigger Assembly, Spar Drilling and Supplemental Long Link Clamps.
Rev M
Page 2
Component and Tool Quick Reference
Note: All components are not required for every installation.
SPAR
(aluminum extrusion)
COMPONENTS
LONGITUDINAL LINK
ANCHOR BLOCK
LATERAL LINK
PIVOT BLOCK
CLAMP BLOCK
TILT BRACKET BASE
TILT BRACKET COVER
(aluminum sheetmetal)
END ROW TILT BRACKET COVER (N/S rows only)
10°, 15°, 20°
DRILL JIG
Rev M
LONG LINK CLAMP
(stainless steel)
5°
Z CLAMP ARM
(stainless steel)
Page 3
BALLAST PAN
COMPONENTS
FLASHABLE POST ANCHOR (FPA)
(machine/welded aluminum)
CONCRETE BALLAST PAVERS
(Not supplied by SunLink.
See www.paversource.com)
•
•
Available in 12”, 16” and 24”.
Minimum six (6) saw horses
(e.g. Stanley 2-way adjustable saw
horses, 32” high, 4” long, 29” wide)
Rubber mallet
1-1/8” wrench
Wire cutters
12” and 24” ballast pans are
designed to work with 12” x 12” x
2” (nominal) pavers weighing 24
lbs each.
16” ballast pan is designed to
work with 16” x 8” x 2” (nominal)
pavers, weighing 18 lbs each.
REQUIRED INSTALLATION TOOLS
Torque wrench
½” wrench
Hex bit drivers –
3/16”, 5/32”, 7/32”
Pliers
Cordless screwdriver with torque
adjustment
9/16” wrench
Drift pin
4
Substrate Installation
Tilt Bracket Cover
3/8”-16 x 2.25” HHCS
TILT BRACKET ASSEMBLY PARTS AND FASTENERS
Tilt Bracket Base
Longitudinal Link/Long Link
3/8”-16 hex nut
PREP STEP – Create Bending Jig
A. Bend two (2) Tilt Bracket Covers over a Longitudinal
Link.
(More detail about bending in step 2 below.)
B. Attach each Tilt Bracket Cover to a Tilt Bracket Base.
(More detail about base attachment in step 3 below.)
C. Attach the Longitudinal Link between the two Tilt
Brackets using two (2) 3/8”- 16 x 2.25” HHCS and 3/8”
Hex nuts through the upper Tilt Bracket hole.
(Note: HHCS quantity and placement is different for
actual substrate assembly as detailed on next page.)
D. Bending Jig is now ready to be used.
Step 1 – Bend Tilt Bracket Covers
A. Lay each Tilt Bracket Cover over the Bending Jig and
bend the sides of the cover inward.
B. Be careful not to over-bend.
C. Bent Tilt Bracket Covers will have a little spring back.
Step 2 – Insert Tilt Bracket Covers Into Tilt Bracket Base
A. Lower the Tilt Bracket into the Tilt Bracket Base.
B. Pinch the Tilt Bracket Cover slightly
C. Align locking tabs with slots.
D. Release Tilt Bracket Cover and guide locking tabs
through slots.
E. Ensure all locking tabs are completely engaged.
Step 3 – Assemble the Substrates
A. Set up pairs of Tilt Brackets at each desired location.
B. Attach a Longitudinal Link between each pair of Tilt
Brackets by aligning the innermost holes.
C. Use four (4) 3/8-16 x 2.25” HHCS, eight (8) 3/8” flat
washers and four (4) 3/8” hex nuts to attach each
Longitudinal Link to each pair of Tilt Brackets.
(Use two (2) washers per bolt - one on each side of the
Tilt Bracket.)
Note: Do not fully tighten the nuts.
Note: if system is high wind, please request the Deep
Long Link Addendum from your project manager.
Rev M
Page 5
Panel Assembly
Spars
5/16” – 18 x .625 BHCS
and 5/16” hex flange nut
OR ¼” -20 x .625 BHCS
and ¼”-20 hex flange nut
PANEL ASSEMBLY PARTS AND FASTENERS
Clamp Blocks
Anchor Blocks
5/16” – 18 x .625 BHCS
3/8”-16 x 2.25” HHCS and
3/8”-16 hex nut
Pivot Blocks
3/8”-16x2.25” HHCS
PREP STEP – Prepare Saw Horses
A. Lay out saw horses as shown.
B. Distance between first and last saw horse should be
approximately 12” shorter than Spar being used.
Note: Placing plywood sheets on the saw horses
provides a larger work surface for holding tools and
components.
Step 1 – Attach modules to Spars
A. Lay modules face down with an approximate module to
module gap of 1.25”.
B. Lay two (2) Spars on top of the edges of the modules.
C. Position modules so that the junction box on every
module faces the same direction.
D. Depending on module and mounting hole diameter, use
either four (4) 5/16-18 x .625” BHCS or four (4) 1/4 – 20
x .625” BHCS with corresponding flange nuts per
module. Spars with Ø.28” mounting holes use 1/4”
screws and Spars with Ø.34” holes use 5/16” screws.
E. Leave nuts loose.
Step 2 – Insert Clamp Blocks
A. Insert Clamp Blocks to ensure equal spacing between
modules. Install three (3) Clamp Blocks per 4x1 Spar,
three (2) Clamp Blocks per 3x1 Spar and one (1) Clamp
Block per 2x1 Spar using one (1) 5/16-18 x 1.25” BHCS
per Clamp Block.
Note: If the PV module is less than 32mm (i.e. Solar
World V2.5), bolt length is reduced to 5/16-18x0.625”.
Note: Clamp block flanges must be positioned flush over
each module and square with the Spar.
B. Tighten Clamp Block and mounting bolts to 11-14 ft lbs
using cordless screwdriver. Ensure cordless screwdriver
is set to the correct torque. During this process make
sure the Spars are seated, with no gaps, against the
outside of the PV module frames.
Rev M
Page 6
Panel Assembly
Step 3 – Attach Pivot Blocks to Spars (on South Spar)
A. Install two (2) Pivot Blocks onto the first Spar using
3/8”-16 x 2.25” HHCS, two (2) per Pivot Block. Tighten
to 16-20 ft lbs.
Note: It may be necessary to lightly tap the Pivot Block
into place using a rubber mallet.
Step 4 – Attach Anchor Blocks to Spar (on North Spar)
A. Install two (2) anchor blocks onto the second Spar using
two (2) 3/8”-16 x 2.25” bolts and 3/8” hex nuts.
B. Rotate anchor block so that grooved surface is facing
modules.
C. Tighten to 16-20 ft lbs.
Note: Depending on movement of panels on site, the
anchor blocks can be attached to the Tilt Brackets first.
The anchor blocks would then be attached to the Spar
after the panel is installed on the Tilt Brackets.
Rev M
Page 7
Panel Installation
3/8”-16 x 2.25” HHCS
PANEL INSTALLATION PARTS AND FASTENERS
3/8”-16 hex nut
3/8” flat washer
Step 1 – Attach Panels to Substrate
A. Attach the assembled panels to the Tilt Brackets.
B. Position the assembled panels up 90° and guide the Pivot
Blocks into the Tilt Brackets on the south side as shown.
Step 2 – Attach Anchor Blocks to Substrate
A. Rotate the panel down and guide the anchor blocks into the
north side Tilt Brackets as shown.
B. Install two (2) 3/8-16 x 2.25” HHCS with a 3/8” flat washer
into each anchor block and attach a 3/8” flat washer and
3/8” hex nut on each bolt. Do not tighten.
C. Install two (2) 3/8-16x2.25” HHCS with 3/8” flat washers
into each Pivot Block and fasten with 3/8” flat washers and
nuts.
Note: If SunLink layout calls for use of inriggers, please
request Inrigger Addendum from your project manager.
Step 3 – Torque Substrate Bolts
A. Once all bolts are installed and panels are in position tighten
all eight (8) mounting bolts to 16-20 ft lbs.
Rev M
Page 8
Lateral Link Installation
Lateral Link
LATERAL LINK INSTALLATION PARTS AND FASTENERS
3/8”-16 x 2.25” HHCS
3/8”-16 hex nut
Lateral links provide connection in the East/West direction and are an
important component in the overall design of the SunLink RMS.
Step 1 – Attach Lateral Link to Spar
A. Identify Lateral Link locations where shown between
panels on layout drawing.
B. Insert the Lateral Link within the Spar channel of each
panel and align mounting holes.
C. Install two (4) 3/8 - 16 x 2.25” HHCS through Spar and
Lateral Link (2 each end) and attach four (4) 3/8” hex
nuts.
D. Tighten to 16-20 ft lbs.
Note: If there is an offset between adjacent panels,
shim the Tilt Bracket Base to level.
Rev M
Page 9
Tilt Access Feature
Tilt Access™ lets you flip the panels up and out of the way to access
the underside of the modules during installation and routine
maintenance.
Step 1 – Engage Tilt Access
A. Remove both 3/8”-16x2.25” HHCS’s from the Anchor
Block/Tilt Bracket assemblies and one from each of the
Pivot Block/Tilt Bracket assemblies.
B. Lift the sub-assembly (4x1 and 3x1) up to 100 degrees.
C. Align the provided locking holes on the Tilt Bracket with
the locking holes on each Pivot Block.
D. Place one 3/8”-16x2.25” HHCS into the locking holes on
each of the two Tilt Brackets.
Note: Tilt Access™ feature is allowed without additional
support in wind speed less than 15mph. Should not be
used when wind speeds are greater than 15 mph.
Should not be left engaged overnight.
Rev M
Remove one 3/8”-16x2.25”
HHCS from this location.
Install 3/8”16x2.25” HHCS
in Tilt Access
locking hole.
Page 10
Ballast Pan Installation
BALLAST PAN INSTALLATION PARTS AND FASTENERS
Ballast Pan
(12” wide x 27.7” long, 16” wide x 35.3” long or
14 gauge SS wire (0.08” dia.)
24” wide x 27.7” long)
Note: SunLink Recommends installing Ballast Pans after the panels
have been installed on the substrate.
Step 1 – Place Ballast Pans
A. Place Ballast Pan over Longitudinal Link and keep pan close
to the north row Tilt Bracket Cover.
Note: Refer to your SunLink layout for location specifics.
Step 2 – Place Ballast
A. Lay required number of pavers into Ballast Pan.
Note: Refer to your SunLink Wind Load Report.
B. Push pavers as close as possible to the Long Link.
Note: Check your SunLink layout for details as to how you
should stack your ballast blocks.
24” ballast pan with 8 pavers
16”ballast pan with 4 pavers
Step 3 – Place and Affix Tie-Down Wire
A. Loop wire though hole on side of Ballast Pan.
B. Twist it around itself (two twists minimum) to secure.
C. Pull wire taught.
D. Loop through hole on other side of Ballast Pan.
E. Secure by twisting wire around itself (two twists minimum).
F. Repeat steps above for second wire.
Alternate Step 3 (only for stacks of 4 pavers high or less)
A. Loop wire through holes on one side of Ballast Pan.
B. Remove slack and loop ends through opposite side of Ballast
Pan.
C. Twist wire around itself (two twists minimum) to secure.
Rev M
Alternate Step 3:
Page 11
Flashable Post Anchor Installation
FLASHABLE POST ANCHOR INSTALLATION PARTS AND FASTENERS
Flashable Post Anchor
5/16”- 18 x .625” Button
Z-Clamp Arm
(6.5” post, standard base, ¾”-10 thread)
Head Cap Screw
¾”-10 x 1.5”
Long Link Clamp
Flat washer for ¾” screw
Hex Head Cap Screw
Step 1 – Install Flashable Post Anchor
A. Install Flashable Post Anchor components at locations
shown on your SunLink layout.
B. Remove section of roofing material to allow direct access to
substrate.
C. Insert backer board (not supplied by SunLink) to bring
connector base flush with deck.
D. Attach SunLink-supplied Flashable Post Anchor to backer
board using mounting screws (not supplied by SunLink).
E. Add flashing (not supplied by SunLink).
Step 2 – Connect Z-Clamp Arm to Long Link and FPA
A. Attach Z-clamp arm to long link using long link clamp and
four (4) 5/16 - 18 x .625” BHCS with 5/16” flange nuts. Do
not tighten nuts.
B. Attach Z-clamp arm to FPA and secure with 3/4 -10 x 1.5”
HHCS and flat washer.
C. Tighten to 30-40ft lbs. Tighten 5/16" nuts on long link clamp
to 11-14 ft lbs.
Rev M
5/16” Flange Nuts
With flashing installed.
Z-Clamp Arm
Flashable Post Anchor
Page 12
Spar drill jig
Vise-grip plier’s clamps (2)
(See McMaster-Carr Part #2105A14)
SPAR FIELD DRILLING TOOLS
13/32” metal cutting drill bits
(minimum 2 per job)
Cordless screwdriver with
torque adjustment
9/16” wrenches or sockets
Spar field drilling is required when a column of 4x1 transitions to a 3x1 (or vice versa).
Refer to your SunLink layout drawing to determine if Spar drilling is required for your system.
South
3x1 to the north of a 4x1.
Connect to 4x1 using Anchor Block.
3x1 to the south of a 4x1.
Connect to 4x1 using Pivot Block.
Method A (best practice) – Drilling the Spars Before Attaching them to Modules
Step 1 – Drill Holes to Allow Attachment of Pivot or Anchor Block
Note: Appropriate use of either Anchor or Pivot Block is
determined by whether the 3x1 is to the north or south of the 4x1.
A. Determine which side of the 4x1 Spar needs the extra
mounting holes.
B. Lay a 3x1 and 4x1 Spar back-to-back and align one set of
Anchor/Pivot Block holes on the 3x1 with the matching
holes on the 4x1.
C. Clamp and bolt Spars to affix Spars together and maintain
alignment.
D. Affix the Drill Jig to the 3x1 Spar at the second Pivot/Anchor
Block Location. Tighten thumbscrew to secure Drill Jig.
E. Using the Drill Jig as a guide, drill two 13/32” holes in the
4x1 Spar.
F. Debur edges on both sides.
G. Attach the Pivot Block or Anchor Block to the Tilt Bracket of
the 4x1.
Rev M
Side View
Page 13
Method B – Drilling Spars After System is Mounted on The Roof
Note: Appropriate use of either Anchor or Pivot Block is determined by whether the 3x1 is to the north or south of the 4x1.
Step 1 – Drill Holes to Allow Attachment of Anchor Block
A. Use Anchor Block as a guide to ensure that the Drill Jig
is in the correct location.
B. Push Drill Jig into Spar until it stops. Secure Drill Jig to
Spar using jig thumb screw.
C. Drill two 13/32” holes in 4x1 Spar.
D. Debur edges on both sides.
Drill Jig
Anchor Block used as guide
Tilt bracket of 3x1
Step 2 – Drill Holes to Allow Attachment of Pivot Block
A. Use Tilt Access to lift 4 x1 panel up to gain access to inside
of lower Spar.
B. Use Anchor Block as a guide to ensure that the Drill Jig is in
the correct location.
C. Push Drill Jig into Spar until it stops.
D. Secure Drill Jig to Spar using jig thumb screw.
E. Remove Anchor Block.
Note: Anchor Block is only used as a guide, a Pivot Block will
be used to connect the 3x1 Tilt Bracket to the 4x1 Spar.
F. Drill two 13/32” holes in 4x1 Spar.
G. Debur edges on both sides.
Rev M
Drill Jig
4x1, South side of Spar
Anchor Block used as guide
Page 14

Assembly Instructions for SunLink RMS

Transcription

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