ASSEMBLY INSTRUCTIONS FOR SLK SOLAR PV .Assembly instructions for SLK Solar roof mount system

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  • AssemblyinstructionsforSLKSolarroofmountsystemRevL Page1of38

    ASSEMBLYINSTRUCTIONSFORSLKSOLARPVMODULE

    ROOFMOUNTSYSTEM

    TABLEOFCONTENTS

    Noticesandsafety Page2Generalprocedurenotes Page4Installationmaterialsandtools Page5Partdiagrams Page5ElevationViews Page7Assemblysequence Page9Tiltbracketassemblyandinstallation Page10Substrateassembly Page12Panelassembly: 4x1&3x1 Page13

    Generalmoduletospargrounding Page17TiltAccessFeature Page18Panelinstallation Page19 Laterallinkassembly Page21Winddeflectorassembly Page22Ballastpaninstallation Page28Connectorinstallation Page32Sparfielddrilling Page34

  • AssemblyinstructionsforSLKSolarroofmountsystemRevL Page2of38

    NOTICESANDSAFETYPRECAUTIONSReadthisdocumentbeforebeginninginstallationwork.Planforsafepracticeduringanyinstallationactivitywithrespecttohazardsfromtripping,falling,lifting,repetitivestress,andanyoverheadorelectricalhazards.Whenworkingclosetobuildingroofedges,considerprotectionoptionsthatreduceworkerexposuretofallhazards.RefertoOSHASubChapter7,Group1,Article2.TheSLKSolarRoofMountSystem(RMS)ismadefromaluminumalloy,fastenedtogetherwithstainlesssteelassemblyhardware.AluminumalloycomponentsaremanufacturedperASTMB209andASTMB221.5052H32isusedforsheetmetalcomponents,andtempered6000seriesalloysareusedforextrudedcomponents.IntheformsusedinSLKSolar,thesematerialsareconsideredtobenontoxic.Metalcomponentsoftenhavesharpedges.Handlecarefully!Wearingglovesisgoodpractice.Thisdocumentisnotprescriptiveregardingsafetyanddoesnotpurporttoaddressallthesafetyconcernsthatmayarisewithitsuse.Contractorsshouldbecomefamiliarwithallapplicablesafety,healthandregulatoryrequirementsbeforebeginningwork.ElectricalsafetynoticeAnytimeaSLKSolarpanelcontainstwoormoreelectricallyinterconnectedmodules,ashockhazardispresent.SLKSolarisamechanicalsystemandcontainsnoliveparts.Mechanicalinstallersandelectriciansshouldcoordinateinordertoensurethatallpersonnelareawareofelectricalhazards.PrecedenceTheSLKSolarRMSpositionsandsecuresphotovoltaicmodules.DCstringingandinterconnectionofthemodulesrequiresplacementofconduit,conduitfittingsandcombinerboxes.Nothinginthisdocumentisintendedtolimittheallocationofrooftopspaceortocontrolcraftswithrespecttoworkprecedenceandcoordination.BuildrateEstimatedmechanicalinstallationrate(modulesperday)foranarrayconsistingofcommercialclassmodulesinstalledwithaSLKSolarRMSandassumingawellequippedfourpersoncrewisontheroofandworking7.5hours/daywithfulltaskinterchangeability:>120modules/day.AsbuiltdocumentationprocessOnroofuseandmarkupofthisdocumentandthedrawingsandprintedmatterreferredtointhisdocumentisgoodpractice.Markupandannotatethedrawingsonaregularbasis,notingcompletions,exceptions,dimensionalinconsistencies,etc.FieldmodificationsUnauthorizedfieldmodificationofSLKSolarcomponentsorassembliesmayaffectSLKSolarwarrantycoverage.ProvidemarkedupdrawingsforSLKSolarsreview,commentandapprovalpriortoattemptinganyfieldmodifications.WorkaroundsWorkerslayingoutorinstallingarraysonrooftopsmayencounterundocumentedorunexpectedobstaclesrequiringaworkaround.SincePVarraysareintendedtobeprimarilyregularandrepeatingstructures,workaroundsshouldbenotedonworkingdrawings.Whenaworkaroundaffectsthelocationoftwoormoremodulesatonce,thesupervisorshouldbeadvisedandtheworkaroundshouldbeevaluatedandthencompletedinamannerthatensuresthattheremainderofthearrayisnotaffected.RoofsurfaceAlllargeflatroofshavepitchandundulation,jointedassemblies,andmayalsohavelevelseparationsandparapets.Variousroofmountedfittings,airventpipesandequipmentsuchasHVACorprocessequipmentmayalsobeencountered.Thepreciselocationofmanyrooftopdetailsisnotknownsincesuchdetailsareinstalledunderconditionsinwhichtheworkerorcontractormayhavediscretionregardingfinallocation.FireSafeRoofTheSLKSolarRMSistobemountedoverafireresistantroofcoveringratedfortheapplication.TheSLKSolarRMSisnotmeantforslopedroofswheretheslopeisgreaterthan1:12(7or12%).

  • AssemblyinstructionsforSLKSolarroofmountsystemRevL Page3of38

    FitupSLKSolarisadesignedfitsystemandisassembledusingfastenersandassemblyboltsets.Matchingholelocationsareengineeredtoensurelongtermreserveassemblystrengthandlifecyclereliability.Sinceundulationandslopeisrequiredtoensureroofdrainage,SLKSolarincorporatesfeaturesthatallowthearraytofollowtheroofcontour.Lineupforfinalboltedconnectiontypicallyinvolveslightbuckinginduringassembly.Adriftpinisausefultoolwithwhichtoalignholesforcrossbolting.RooflifeandcareTheservicelifeofanyroofiscontingentuponcarefortheroofespeciallyduringequipmentinstallationonaroof.Avoidconcentratedloadsontheroof.NeverdragSLKSolarcomponentsintoplace.Instead,elevatethecomponent,andthenmoveitmanuallyorwithacart.Locateitandthenplaceitonspot.Toensureroofingsystemwarrantycontinuation,workwithroofingsysteminstallationcontractorstoensureroofingsystemarraycompatibility.WARNING!Singleplyroofsarenotdamagetolerant.Avoidaccumulationofmetalfinesthatresultfromdrillingorsawingmetalcomponents.Metalfinesembeddedinthesolesofshoescandamagesingleplyroofs.FastenersAllrequiredfastenersarefurnishedwiththeSLKSolarRMS.Allfastenersare18Cr8Nistainlesssteel.Foranyassembly,finishinitialboltedassemblytofingertight.RefertotheInstallationManualfordetailedinformationonapplication.Buttonheadcapscrews(BHCS)areprecision,lowprofilefasteners.Useofairpoweredtoolsthatdonotincorporatemeanstolimitappliedtorquemaydamagetheheadofthesefastenersandisnotrecommended.FinalinspectionVisuallyinspectassembledSLKSolararrays,roofmountedorgroundsupported.Thesuggestedprocessconsistsofarowbyrowwalkthroughandthenaperimeterwalkaround,aftermechanicalassembly,beforeelectricalcompletion.ReportanydistortionintheassemblytoSLKSolar.Arraysubstratesupportsshouldbeinfullcontactwiththeroofortheground.Anyindicationofunevendistributionofweightshouldbeevaluatedandcorrectedbeforecontinuingwithelectricalfinishing.

  • AssemblyinstructionsforSLKSolarroofmountsystemRevL Page4of38

    GENERALPROCEDURENOTESA.TheSLKSolarsystemassemblesmodulesintopanelsasfollows: 4x14modulesassembledintoonepanel 3x13modulesassembledintoonepanel

    2x12modulesassembledintoonepanelB.Tiltbrackets

    TiltbracketsaremultifunctionSLKSolarassemblies.Togetherwithlongitudinallinks,tiltbracketsmakeuptheSLKSolarroofsubstrate.Tiltbracketsenablefreestandingarraysupportandallowformechanicalanchoring.Tiltbracketbasescanbeadaptedtoanyrooftype.Tiltbracketcoverssetthearrayangleofincidence,connectSLKSolarpanelstothesubstratesubsystemandestablisharrayrowspacing.

    Tiltbracketsareconfiguredforeasyfieldassemblyandareshippedintwoparts.Tiltbracketcoversareshippedinasemiformedconditionandneedfinalformingtobecompletedonsiteandarethenattachedtothetiltbracketbases.Thisminimizesonsitestorageandreducesshippingandhandlingbulk.

    Assemblytimefortiltbracketisabout10seconds.Theassemblyprocessisworkerfriendly.Asistrueforanyprecision

    assembly,alighttouchworksbest.

    Donotoverbendthetiltbracketcover.C. TILTACCESSisauniquefeaturetoSLKSolarthatletsyouflipthepanelsupandoutoftheway.

    Duringinstallationdonotleavepanelsunattendedinthetiltupposition.Donotplacepanelsinlockedtiltuppositionifwindsexceed15mph.

    D.Temporaryballast

    Attheendofeveryworkday,ensureallcomponentsaresecurelyattached.Temporaryballast(i.e.sandbags)mayberequiredtosecurethesystemtotheroofduringtheinstallationprocesstopreventmovementordamageduetowind.

    E.Safety

    Foralldayhandlingofaluminumcomponents,weargloves.

    Becarefulofpinchhazards,especiallywhenloweringpanelsontotiltbrackets

  • AssemblyinstructionsforSLKSolarroofmountsystemRevL Page5of38

    REQUIREDINSTALLATIONMATERIALSANDTOOLS

    1. Minimumsix(6)sawhorses(e.g.Stanley2wayadjustablesawhorses,32high,4longand29wide.Stanleypartnumber11012)

    2. Torquewrench3. Cordlessscrewdriverwithtorqueadjustment4. Rubbermallet5. 1/2wrench6. 9/16wrench7. 11/8wrench8. Hexbitdrivers3/16,5/32,7/329. Driftpin10. Wirecutters11. Pliers

    PARTDIAGRAMS

    Spar(aluminumextrusion)

    Longitudinallink(aluminumextrusion)

    Anchorblock(aluminumextrusion)

    Laterallink(aluminumextrusion)

    Pivotblock(aluminumextrusion)

    Clampblock(aluminumextrusion)

    Tiltbracketbase(aluminumsheetmetal)

    Tiltbracketcover(aluminumsheetmetal)

    Endrowtiltbracketcover(Aluminumsheetmetal)

  • AssemblyinstructionsforSLKSolarroofmountsystemRevL Page6of38

    PARTDIAGRAMS

    Eastwinddeflector(aluminumsheetmetal)

    Westwinddeflector(aluminumsheetmetal)

    EndEastdeflector(aluminumsheetmetal)

    EndWestdeflector(aluminumsheetmetal)

    Enddisc(aluminumextrusion)

    Deflectorclip(Stainlesssteel)

    Drilljig

    Longlinkclamp(stainlesssteel)

    ZClampArm(stainlesssteel)

    Ballastpan(aluminumsheetmetal)

    Flashablepostanchor(FPA)(machined/weldedaluminum)

  • AssemblyinstructionsforSLKSolarroofmountsystemRevL Page7of38

    ELEVATIONVIEWOF5SYSTEM(notetiltbracketsaretransparentforclarity)

    ELEVATIONVIEWOF10SYSTEM(notetiltbracketsaretransparentforclarity)

    PVModule

    Tiltbracket

    Pivotblock

    Anchorblock

    EndDisc

    Winddeflector

    Spar

    Clampblock

    Laterallink

    Endrowtiltbracket(smallersizethantiltbracket)

    Winddeflector

    Northendrowtiltbracket

    Anchorblock

    Tiltbracket

    ClampblockPVModule

    PivotblockEndDisc

    LongLink

    Spar

    Tiltbracket

    Endrowtiltbracket(smallersizethantiltbracket)

    LongLink

  • AssemblyinstructionsforSLKSolarroofmountsystemRevL Page8of38

    ELEVATIONVIEWOF15SYSTEM(notetiltbracketsaretransparentforclarity)

    ELEVATIONVIEWOF20SYSTEM(notetiltbracketsaretransparentforclarity)

    Winddeflector

    Laterallink

    Clampblock

    Pivotblock

    Anchorblock

    Enddisc

    Spar

    Tiltbracket

    PVModule

    Endrowtiltbracket(smallersiz