Installation MANUAL - Olympic Energy Systems...Tensioned cables in roof mount systems (R í and R î) have a “hold down” role, with much of the panel ... holding up significant

Olympic Energy Systems, Inc.

1

PRELIMINARY

Tensioned Cable System (TCS)

Installation

MANUAL

For Implementing

Solar Panel Mounting Kits

(TCS-G1-#-##)

GROUND

REV NEW Draft 6/21/2012

Technical Support: (360) 301-5133

www.olympicenergysystems.com

Ground Mount Kit

(Example)

Pre Release Copy

http://www.olympicenergysystems.com/


2

Roof

Ground


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Foreword

The Tensioned Cable System (TCS) for mounting solar PV panels has been under development since

March 2009. Prototyping through December 2010 culminated in a pre-production model (TCS-G1-2-12)

installation in Sequim, Washington (USA) in late December 2010. A production roof top version was

installed in January 2011. As the ground TCS is more complex and challenging to develop, most of 2011

was spent on evolving the sub-component designs – PV Clamps, PV Hangers, Mid-Stanchion Hardware

(for cable pass-through), and anchoring. As such, the Installation Manual remains in a very early stage.

The plan calls for using the installation experience from the University of Findlay solar project (using two

G1 units for a total 2.7 KW) to develop the initial Installation Manual. The TCS G1 Installation Manual –

Revision NEW – should be available by Spring 2012.

Jonathan A. Clemens

President

12/29/2011

The first production TCS G1 was installed in Findlay, Ohio during the week of June 4, 2012, with a

successful utility grid-tie functional test on June 6 and readiness for inspection achieved on June 8, 2012,

with completion of the electrical ground wiring. It is expected that a single row G1 can be completely

installed – mount, anchors, PV panels, and wiring - by a two-man crew in one day.

JAC

6/14/2012


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Table of Contents

1 Introduction

Safety Precautions

Required Tools

Site Assessment

Patent Pending - Key Attributes

TCS System Description

Basic Principles

2 TCS System Specification

Ground Mount

System Kits

Part Numbering

Solar PV Panel GROUPING

Installation Support

3 TCS Mounting Kit Selection

Recommendations (Tips, Rules of Thumb, and Lessons Learned)

System Schematic

System Components

4 Pictorial Assembly Sequence

General Assembly Instructions

Detail Assembly Procedures

Special Procedures

PV Panel Removal

Re-Tensioning

Disassembly

Inclement Weather Preparation

5 Maintenance

6 Design Science Plan for Tensioned Cable Systems

7 Certifications and Approvals

8 Warranty Information

9 Glossary of Terms

Appendix


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1 Introduction

This manual is intended for use by purchasers, users, and installers of the Tensioned Cable System solar

panel mounting kits that use tensioned cables and no roof penetrations and no ground foundations.

As with any alternative to a conventional product or technique, there is a learning curve. The learning

curve around tensioned cables is “f-a-s-t-e-n-a-t-i-n-g”, as there are insights revealed once the principles

are understood. Though installation by licensed contractors is generally preferred, any intuitive

individuals can install the mounting system and the PV panels that clamp to it.

Safety Precautions

Be mindful when handling the system components during assembly: Sharp Edges on fabricated metal

parts, sharp cable ends from the cut wire rope (which tends to fray and present single strands that can

puncture skin), heavy weight of the stanchions (weighing over 40 pounds), high voltage on the PV panel

cables (presenting a shock hazard), and trip hazards from the anchored end cables.

Required Tools

Measuring Tape

Level

Socket Wrench Set

Pop Riveter

Pry Bar (self-made model shown herein)

Shovel (optional, or as needed to begin anchoring)

Cable Snips, 1/4 inch capable (optional to remove excess length)

Site Assessment

Soil Condition

Earth Anchors can function in a range of soil types, from hard and gravelly soils of the Northwest to the

relatively soft clayey soils of the Midwest and Eastern USA. Pull out strength (shear strength) varies

widely with soil type. Clay soils lose shear strength in the presence of water, which tends to suspend

and not percolate – larger Earth Anchors with a wider Helix and longer shaft are used in clayey soils.

Auger type anchors can be used in sandy soils.

Small rocks, buried gravel layers (from old foundations, etc.), and pebbles can present a problem during

anchoring. Usually, small relocations of the anchor point can find a region free for anchoring. A small

hole may be dug to get through the soft soil on type to facilitate the “threading” of the earth anchor. A

professional should be consulted if the soil is found to be soft or regularly saturated with water.

Pictures below illustrate what one may experience while testing the soil and anchoring during a site visit.


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A site layout and anchor test revealed a hidden layer of gravel 4 inches thick, likely a remnant of an old

driveway or house with no basement. No problem, as once you dig through the gravel, untouched soil

(clay in this case) is accessible and ready to accept the anchor.

Both anchors at each end were started about 62 inches from the pier block base, initially vertical, and

tilted progressively after each turn until an approximate angle for the end cable is reached.


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Solar Access (percentage of annual energy captured)

Obstructions to the south can be visually assessed, but is quite thoroughly done with use of a Solar

Pathfinder Tool. Olympic Energy Systems provides a free assessment and an estimate of the year’s

access to the sun, as a percentage of the potential Peak Sun Hours (noon equivalent).

Mounting Surface or Area

The mounting system footprint is found in the TCS Specification , and includes the physical dimensions

from the anchor insertion points (left to right) and stanchion post edges (front to back). Note, PV panels

may extend to the front or to the back of the mounting system.

Integration with Site Electrical Supply (for grid-tie applications)

The electrical interface to the solar PV panels and mounting system must comply with local electrical

codes. Typically, the DC cables from the array are buried in conduit, perhaps from a Combiner Box

located at or near the array. The general approach is to the rear of the TCS G1, at or near the Mid-

Stanchion. Multiple rows of G1 will mean multiple groups of wiring, which will usually be buried in

conduit. Place buried conduit away from the stanchions and anchors. Though allowable, above ground

rails or trays from securing the PV cable runs may present a tripping hazard.

Beyond the outdoor rated (USE 2) PV cables used from the PV panel pigtails (usually via MC connectors),

all DC cable must be in conduit. Conduit may be (gray/outdoor rated) PVC. Junction Boxes with glands

may be used to transition the USE cables into the conduit.

Patent Pending – Key Attributes

Tensioned Cables Solar Panel Mounting System (Roof Mount) patent application filed March 15, 2010,

with the following key attributes:

Tensioned Cables, Gable Mount (“C” Mount), Eave Mount (similar to Gable Mount), Pivot Joint, Lift

Tensioner, PV Clamp (Mid and End), Rails (off the shelf) used in conjunction with Tensioned Cables

NOTE: Peak Mounts have been added to the design.

Dual Opposing Catenary Solar Panel Mounting System (Ground Mount) patent application filed March

15, 2011, with the following key attributes:

Tensioned Cables, Dual Opposing Catenary (Cables), Thrust Plates with Integral Tensioning, Stanchion,

Geometry for Stability held down via Earth Anchors, PV Clamp (Dual - PV and Cable)

NOTE: The Dual Clamp design is replaced with Hanging Style Clamps.


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TCS System Description

Mounting Kits are available for roof and ground mounting of framed solar panels. Design evolution will

eventually take us to mounting thin film PV without frames. This is part of an anticipated Design Science

leading us to do more with less.

Tensioned cables in roof mount systems (R1 and R2) have a “hold down” role, with much of the panel

and rail weight supported by Peak Mounts that “hook” onto the peak. Bulk tensioning is provided by Lift

Tensioners on the surface of the roof. Fine tensioning is provided by Pull Tensioners attached to the C-

shaped C-rings of the Gable Mount.

Tensioned cables in ground mount systems (G1 and G2) have a “hold-up” role, with tensioned cables

holding up significant weight, and with an exposure to wind, necessitating dual opposing cables to

provide stability. The shape, size, and geometry of the stanchions also provide stability, especially in

winds. Integral tensioning is provided by eye bolts in the Thrust Plates on the end stanchions. End

cables attached to earth anchors include turnbuckles, a form of Pull Tensioner that allows a balancing

between the suspended PV cables and the end cables, ensuring that stanchions remain vertical and firm.

In all systems, PV panels are held firm by PV Clamps, with fasteners that attach to rails on the roof and

cables on the ground. The roof PV clamps are different from the ground PV clamps.

Basic Principles

Cable sag is acceptable and in fact useful for achieving relatively low tension forces.

An opposing cable, connected to PV Cables by a series of Cross-Ties (CT’s), resists the un-sagging of the

PV Cables, as by wind; forms a Dual Opposing (Catenary) Cable (DOC) System.

The triangular shape of the Stanchions allow for resistance to wind forces, both from behind and front.

Balance of forces is key, yet subtle…End Cable horizontal forces must equal the sum of the PV and DOC

Cables forces; the DOC force must be high enough, relative to the PV Cable force, to minimize the side to

side torque (moment) on the Pier Blocks,

The ground under the Pier Blocks must be firm, compressed, and tamped.

2 TCS System Specification


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TCS G1 System Specification

Parameter G1-2-8 G1-2-10 G1-2-12 G1-2-14

Footprint 4’ x 27’ 4’ x 31’ 4’ x 35’ 4’ x 40’

Tilt Angle 30 degrees 30 degrees 30 degrees 30 degrees

Linear Feet – PV 11 feet 14 feet 18 feet 22 feet

Number of PV 4 - 6 6 - 8 6 - 10 8 - 12

Anchor Size 4”x40” gravelly

6”x45” clayey

4”x40” gravelly

6”x45” clayey

4”x40” gravelly

6”x45” clayey

4”x40” gravelly

6”x45” clayey

Max Cont. Wind 60 mph 60 mph 60 mph 60 mph

Peak Wind Load 90 mph 90 mph 90 mph 90 mph

Weight – End

Stanchions

60 lbs 60 lbs 60 lbs 60 lbs

Weight – Mid

Stanchions


Weight –

Hardware w/o

Stanchions/Anchors


Lifetime 20 Years + 20 years + 20 years + 20 years +

Material – TP

– Cables

– Clamps

– Hangers

– Stanchions

– Earth Anchors

304 SS

316 SS

Aluminum

Aluminum

Treated

Steel/Painted

304 SS

316 SS

Aluminum

Aluminum

Treated

Steel/Painted

304 SS

316 SS

Aluminum

Aluminum

Treated

Steel/Painted

304 SS

316 SS

Aluminum

Aluminum

Treated

Steel/Painted

Warranty 1 year 1 year 1 year 1 year

System Features Integral PV Cable

Tensioning

Failsafe PV Clamps

One person PV install

Dual Opposing Cables

No permanent

foundations

Integral PV Cable

Tensioning

Failsafe PV Clamps



No permanent

foundations

Integral PV Cable

Tensioning

Failsafe PV Clamps



No permanent

foundations

Integral PV Cable

Tensioning

Failsafe PV Clamps



No permanent

foundations


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The Tensioned Cable System (TCS) provides a means for low cost mounting of solar panels on roofs

without penetrations and on the ground without foundations. The key to doing more mounting with

less material is tensioned cables. Cost reductions over conventional means are a result of reduced

material content and simplified installation steps. The design is covered by patent applications in 2010

and 2011, via Patent Attorney Virginia P. Shogren, P.C., of Sequim, Washington at (360) 461-5551.

The mounting system shall accommodate the installation of at least one string (for grid-tie) for any

framed photovoltaic (PV) panel on the commercial market, totaling at least 20 manufacturers and

hundreds of different sizes and electrical outputs.

Ground Mount

The basic ground mount system shall consist of the following components:

PV and End Cables (1/4” Stainless Steel) and Cable Hardware (Clips, Thimbles, and Crimps)

Stanchion Mounts (End and Mid) w/ Cross Support Member

Tension Plates

Earth Anchors (40” minimum shaft length and 4” minimum helix diameter)

Turnbuckle Tensioners (End Cables)

Pull Tensioners (PV Cables)

Cross Ties (between parallel cables) - Straps held permanent with Pop Rivets

PV Cable Clamps (Mid and End)

Pier Block Surface Bases (on Ground)

Keeper Hardware (Mid Stanchion) and Fasteners (hex head screws, nails)

All metallic materials shall be either Galvanized Steel, Painted Steel (anchors), Stainless Steel, or

Aluminum. Stanchions may be fabricated from Treated Lumber or other suitable materials for strength,

longevity, and environmental compatibility. Materials shall be suitable for outdoors and shall not be

hazardous.

System Kits

The basic mounting systems (roof and ground) shall be pre-fabricated and available in kits.

System designs shall provide for a single, pair, or a string of framed PV Panels.

For roof mount systems, there shall be accommodation for variations of landscape or portrait

orientations of different size rows and columns.

For ground mount systems, there shall be accommodation for portrait orientations for all applicable PV

panels.


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Part Numbering

The format of the ground mount system part number shall be OES-TCS-G1-y-zz, where y = number of

spans 1 or 2, and zz = nominal span length 10, 12, 14, 16, or 18 [in feet]. As the length is encoded in the

selected dash number zz, no PV Model # is required, though contemplated on ordering. G1 is version 1.

Sub-Component Number Scheme

SYSTEM TCS-G1- #-##

where # is either 1 or 2, or 8, 10, 12, 14, other [future]

SUBSYSTEM TCS-G1-[STA, CAB, HAN, CLA, CTX, or MSH]-#-##

where STA=Stanchion, CAB=Cable, HAN=Hanger, CLA=Clamp

CTX = Cross Ties (Straps), and MSH – Mid Stanchion Hardware

COMPONENT TCS-G1-[STA, CAB, HAN, CLA, CTX, or MSH]-#-##

where # = Component (depending on Subsystem)

SUB-COMPONENT TCS-G1-[STA, CAB, HAN, CLA, CTX, or MSH]-#-##

where ## = Sub-Component (depending on Component)

Stanchion

0-00 = End Stanchion (pair) Interchangeable with relocation of cross brace, held with threaded fasteners

1-11 = Mid Stanchion (single)

Cable (PV and DOC) and End Cable

1-[8, 10, 12, 14, or other] = nominal cable length/span, one span

2-[8, 10, 12, 14, or other] = nominal cable length/span, two span

#-00 where # = nominal length of END cable including the turnbuckle

Hanger

0-16 = Universal Hanger (extends 16” from top PV cable to top edge of PV Panel)

Clamp

0-[06, 07, 08, 09, 10, 11, 12, 13, 14] = Mid Clamp with S-Clip Length ## x 0.125 inches

[1-7]-[06, 07, 08, 09, 10, 11, 12, 13, 14] = End Clamp with E-Clip (Frame Depth) Length:

1 = 1.34”, 2 = 1.40”, 3 = 1.60”, 4 = 1.68”, 5 = 1.80”, 6 = 1.90”, and 7 = 2.00”


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Example Part Numbers

TCS-G1-2-12 System, Two Span G1 (with Mid Stanchion) with 12 feet per Span, Basic

TCS-G1-STA-0-00 End Stanchion, Basic

TCS-G1-STA-1-11 Mid Stanchion, Basic

TCS-G1-CAB-2-12 Cable, PV/DOC of length 2x12 = 24 feet nominal

TCS-G1-END-7-00 Cable, End of Length 7 feet, included Turnbuckle, nominal

TCS-G1-HAN-0-16 PV Hanger, Universal, allowing for up to 16 inches from cable to PV edge

TCS-G1-CLA-0-06 Mid Clamp with S-Clip = 0.750 inches

TCS-G1-CLA-5-4 End Clamp with E-Clip depth = 1.80 inches and S-Clip = 0.500 inches

TCS-G1-CTX-0-48 Cross Ties (4 inch shortest and 8 inch longest – set of three assumed)

TCS-G1-MSH-0-02 Mid Stanchion Hardware with 2 clamps/cable (originally had just one)

TCS-G1-2-6B [future use] TCS G1 System with 2 spans, to hold quantity 6 Group B PV panels

Bill Of Materials (BOM)

The first production TCS G1 solar panel mounting system, two units of which were delivered to The

University of Findlay in December 2011, can be specified as follows:

(6) Pier Block with Cradle COTS 12” Pier Block w/ Cradle [not shipped, bought locally]

(2) End Stanchion TCS-G1-STA-0-00

(1) Mid Stanchion TCS-G1-STA-1-11

(1) Mid Stanchion Hardware TCS-G1-MSH-0-02

(2) End Cable (back) TCS-G1-END-7 -00

(2) End Cable (front) TCS-G1-END-5-00

(4) PV/DOC Cable TCS-G1-CAB-2-10

(1) Cross Ties TCS-G1-CTX-0-48

(4) Earth Anchor COTS 6” x 45”

(8) Mid Clamp TCS-G1-CLA-0-12

(8) End Clamp TCS-G1-CLA-5-12

(6) PV Hanger TCS-G1-HAN-0-20

COTS = Commercial Off The Shelf


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Solar PV Panel GROUPING (to aid in kit selection)

Selection of TCS mounting kits depends on certain key characteristics or parameters of the multitude of

available Solar PV Panels:

PV Panel WIDTH

PV Open Circuit Voltage

Weight (to a lesser degree)

Upon analysis of these general characteristics, four Groups have been defined to help size and specify

the G1 kits needed to mount a grid-tied string in a portrait orientation.

Group A B C D Width Less Than 30” 30” to 36” 36” to 42” Greater Than 42”

Nominal Width 26” 32” 39” 42” plus

Nominal Weight 30 lbs 35 lbs 40 lbs 40 – 55 lbs plus

Open Circuit

Voltage, typical

22 V 30 V or

44 V

33 – 36 V Various

Available Panels

(Make & Model)

Not Inclusive or

exhaustive

Evergreen ES-C125

Kyocera LPU135

Mitsubishi 130

Caleo 185

BP 175

Canadian 170 M

ET Solar 185

Lumos 185

Mitsubishi 190

Ning Bo 180

Peva Fersa 180

Sanyo HIT 210+

Schott 175

Schuco 175

SET 175

Sharp 165U1

Solar World 175

Sun Power 230

Sun Tech 175

Trina 185

Aleo 230

BP 230

Canadian 170 P

Canadian 240 P/M

DAY4 190

ET Solar 210

ET Solar 280

Evergreen ES-B

(180-195)

Evergreen ES-A

(200-210)

GE 205

Kaneka 60

Kyocera LPU 185

Peva Fersa 210+

REC 205-230

Schott 210

Schuco 200

Sharp 200U1F

Sharp 230A1

Siliken 215-315

Sun Power 305+

Sun Tech 200

Yingli 175

Solar World 220

DA80

(used in prototyping

11/2011)


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Selection of G1 kits from Desired System Size (NUMBER of PV Panels)

TCS G1 Part No. Spans Group A Group B Group C Group D

TCS-G1-1-8 1 3 2 2 1-2

TCS-G1-1-10 1 4 3 3-2 2

TCS-G1-1-12 1 5 4-3 3 3-2

TCS-G1-1-14 1 6-5 5 4 3

TCS-G1-2-8 * 2 6 4 4 2-4

TCS-G1-2-10 * 2 8 6 6-4 4

TCS-G1-2-12 * 2 10 8-6 6 6-4

TCS-G1-2-14 * 2 12-10 10 8 6

* On Grid Capable (with a String Inverter)

Selection of G1 kits from Desired System Size (Total Power in WATTS)

TCS G1 Part No. Spans Group A Group B Group C Group D

TCS-G1-1-8 1 375 350 400 200+

TCS-G1-1-10 1 500 525 600 200+

TCS-G1-1-12 1 625 700 600 300+

TCS-G1-1-14 1 750 875 800 300+

TCS-G1-2-8 * 2 750 700 800 400+

TCS-G1-2-10 * 2 1000 1050 1200 400+

TCS-G1-2-12 * 2 1250 1400 1200 600+

TCS-G1-2-14 * 2 1500 1750 1600 600+

* On Grid Capable (with a String Inverter)


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Installation Support

Background, tips, drawings, pictures, and steps in the installation and maintenance of the TCS mounting

systems should be included in an Owner Manual, aka Installation Manual (this document). Replacement

component parts, with part numbers, will be available. Design, selection, and installation inquiries may

be directed to Jonathan A. Clemens, President, Olympic Energy Systems, Inc. at (360) 301-5133.

3 TCS Mounting Kit Selection

Section 2 addressed Part Numbering, Solar PV Grouping (A,B,C, and D), and Selection of G1 kits for a

desired system size by either the Number of PV Panels or the Total Power in Watts. It is only necessary

to specify high level parameters (system size and PV panel grouping) to order kits, as the Bill of Materials

will specify all the subcomponents.

G1 kits are differentiated by the length of the PV Cables, the quantity of mid and end clamps, and the

lengths of the separator clips (in both the mid and end clamps) and end clip (in the end clamp), as these

are dependent on the frame dimensions of the specific make and model PV panel.

How to use this Guide

Sizing of solar electric systems depends on a number of factors, including the site characteristics, roof

dimensions, economic conditions, owner budget, aesthetics, and equipment availability. Though the

mounting systems herein are specified as kits, one should not assume that system design and sizing is

merely a prescriptive process. There is always more than one way to implement a solar electric system,

thus, several options should be explored, even beyond the charts and tables. Solar PV panels can be

mounted in portrait or landscape orientation and in many different combinations of rows and columns

to achieve minimal string size for tying to the electric grid.

Tables and figures in the manual allow a quick lookup of the wide range of PV array sizes and shapes.

One could start with a system output value (i.e., wattage) and derive the kits that allow mounting, or

one could look at the mounting specification and derive a system size. Embedded in the selection data

are constraints of PV panel size (height and width) and open circuit voltage - key drivers in the mounting

system design. The array voltage and power must meet minimal requirements of the inverter tying the

DC energy of the PV panels to the AC of the electric grid. Use the guide as a reference and use diligence

as a means of assuring the most appropriate system for the new owner.


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Assembly (from Kits)

All hardware needed to mount the specified number of solar panels on the ground is included in the G1

Kits, except for the concrete pier blocks, which are purchased off the shelf in most garden, lumber,

home improvement, or hardware stores.

G1 Kits

G1 kits mount a string of solar PV panels in Portrait on the ground with tensioned cables strung between

stanchions, for a single row, held to the ground with cables attached to earth anchors. Integral pull

tensioners provide for tensioning of PV cables. All hardware is included in kits. Part Number Example:

TCS-G1-2-12 = Ground Mount, 2 Span (w/ mid-stanchion), 12 feet nominal per Span

G2 Kits [Future Release]

G2 kits mount a string of solar PV panels in Portrait on the ground with tensioned cables strung between

two sets of two stanchions, forming two independent rows (a first and second tier), held to the ground

with cables attached to earth anchors. Integral pull tensioners provide for tensioning of PV cables. All

hardware is included in kits. Part Number Example:

TCS-G2-1-10 = Ground Mount, 1 Span (two rows), 10 feet nominal per Span

The G2 is essentially two G1 units without the mid-stanchions, with the rear tier on higher posts, and

placed as two rows one in front of the other (to form a single PV string) at a spacing between rows of

about 20 inches (to allow personnel access for installation and maintenance). The G2 reduces the

ground mount footprint width from about 35 feet with the G1 to about 16 feet with the G2, with an

accompanying footprint depth increase from about 5 feet to 10 feet.

The G2 is used where land space will not allow the longer length of the G1, otherwise, the G2 mounts

the same number of PV panels as the G1.


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Ground Mount Kits can be simpler to specify than roof kits. A single string is mounted on the ground.

As solar panels come in varying widths, the different ground mount kits vary mainly in cable length and

size of earth anchors. A table is shown for a representative set of available solar PV panels. The ground

mount footprint is about 5 by 40 feet. Multiple strings are implemented with multiple mounting kits.

Solar Panel Make

& MODEL

String SIZE

# Panels

System Voltage

VDC

Power Output Watts

GROUND Mounting KIT

PART NUMBER

KIT PRICE (w/out PV)

Retail Kaneka G-SA060

8 368 480 TCS-G1-2-14 CALL Sanyo

HIT Power 200 6 414 1200 TCS-G1-2-10 CALL

Solar World SW175

8 352 1400 TCS-G1-2-12 CALL Sun Power

SPR-210-BLK 8 384 1680 TCS-G1-2-12 CALL

Trina Solar 180-DC01

8 352 1440 TCS-G1-2-12 CALL Others (8)

Medium Voc 10 352 2100 TCS-G1-2-16 CALL

Others (4) Low Voc

16 352 Varies TCS-G1-2-18 CALL

The five PV Panel string examples in the above table tie to the utility grid, as minimum array voltages

allow use with commercially available string inverters (with over ten manufacturers from which to

choose). The lower wattage, and low price per watt, of the Kaneka PV panel offers a relatively low

upfront cost for new owners to tie to the grid, even if micro-inverters (which allows single panel tie to

the grid) were considered.


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OES-TCS-G1-2-12 (Patent Pending) – installs a string of PV for Grid-Tie.

OES-TCS-G1-2-10 – Installs a string of (6) 225 Watt Sanyo HIT PV Panels.


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OES TCS G1 Components shown below:

Clockwise from top: PV Hanger, Mid Clamp, End Clamps (Left and Right), Mid-Stanchion

Hardware, Cross Ties (stainless steel), and ready to ship (2) sets of TCS G1 with Stanchions


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Recommendations (Tips, Rules of Thumb, and Lessons Learned)

The roof mount kits install with relative ease, as there are no roof penetrations to map out and there is

no balance of PV weight with cable tension as required with the ground mounts. Mounting on the

ground has the distinct advantage of not having to work on a sloping surface. With patience, the loading

of PV panels and the tensioning of cables with the ground mount units become second nature, as one

begins to understand that balancing forces is a matter of small tweaks and of anticipating tensions set

up when all panels are in place. The system has adjustability built in, so the key is the final tensioning,

not the small tweaks along the way to completion.

See “Basic Principles” in the TCS Description section.

System Schematic

Single Span with Dual Opposing (Catenary) Cables

Dual Span

System Components

See next


21


22

Mid Stanchion Hardware

The pass through cables are clamped via lag bolts to prevent slippage.

End Clamp Mid Clamp PV Clamps (Mid and End)


23

PV Hanger

PV Hanger on top PV Cable


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EARLY PROTOTYPES (Historical Only)

Initial Prototyping in July 2009 re Roof (Eave to Eave) – Port Angeles, WA

Prototyping in July 2010 re Roof (Gable to Gable)

Prototyping in December 2010 re Roof (Peak Mount)

Prototyping in September 2010 re Ground (Stanchions) – Findlay, OH

Prototyping in September 2010 re Ground (Single Span)

Prototyping in September 2010 re Ground (Simulated PV)

FOR ILLUSTRATION ONLY (pre-production mounting of simulated PV Panels)

One side then the other (simulated PV panels) - Assembly proceeds inward (starts w/ least sag)

Representative mounting w/ simulated PV panels - PV mounting beginning at the center is intended.

PV Hanger has a series of indents to capture cable [superseded by new design]


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Pictorial Assembly Sequence

The R1 Roof Mount system is shown here to illustrate the relative simplicity of the G1 Ground

Mount…the ground mount is closer to a deployment rather than a fabrication.

Kits are delivered w/ all hardware except Uni-Strut

Small arrays can be pre-assembled before mounting

Small rails can be carried up a ladder and placed

PV Clips hold the PV panel prior to clamping

GM Mount w/ Pull Tensioner (Pad not installed yet)


26

TCS G1 Pictorial Assembly Sequence

1 2

3 4

5 6

7 8


27

9 10

11 12

13 14

15 16


28

17 18

19 20

21 22

23 24


29

25 26

27 28

29 30

31 32

SEE Detail Assembly Procedures


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4 General Assembly Instructions

NOTE: Step numbers do not correspond to pictorial sequence – SEE Detail Assembly Procedures

1) Locate Footprint (array facing south; 4’ x 35’ or 40’).

2) Roughly position Pier Blocks (End-Mid-End).

3) Place Stanchions in Cradles on Pier Blocks.

4) Install End Cables into Thrust Plates (w/ Should bolt).

5) Thread Earth Anchors directly out from Shoulder Bolt on the End Stanchion, beginning 6 feet

from the rear bolt horizontal, and 6 feet less 18 inches from the front bolt horizontal.

6) Connect End Cables to loop on Earth Anchors. Adjust Turnbuckles to leave Stanchions

approximately vertical.

7) Lay out all PV/DOC cables onto ground and adjust cable clips to assure all are the same length

w.r.t the “shortest” cable – about 22 to 22 ½ feet for the G1-2-10.

8) Install PV/DOC Cables [loosely] by inserting the Eye Bolts into the Thrust Plates and attaching

the nuts and washers on the outside.

9) Loosely connect the other End Cables; adjust length of 2nd set of End Cables to approximately

the same length as the first set.

10) Position the Earth Anchor start point (for 2nd set) to reflect the position of the opposite anchors

(1st set); install Earth Anchors.

11) Attach 2nd set of End Cables to the Earth Anchors.

12) Snug up all cables (End/PV/DOC) to obtain balanced forces and End Stanchions tilting slightly out

and Mid Stanchion vertical.

13) Trenching (for electrical) to Mid Stanchion to avoid Pier Blocks and Anchors, TBD.

14) Initially tension up the DOC (opposing cable under the PV Cable), adjusting the End Cable

Turnbuckles to maintain slight tilt out on End Stanchions.

15) Lightly tension the PV Cables, upper and lower.

16) Install Cross Ties; same quantity per span as PV panels; n=3/span for HIT225A on G1-2-10.

17) Hang (fasten) PV Hangers to reflect mid points of the PV Panels onto upper PV Cable; Cross Ties

must be placed adjacent to the PV Hangers and toward the Stanchions (“uphill”).

18) Hang the PV Clamps (Mid and Left End/Right End) onto upper and lower PV Cables at the

approximate location of PV panel frame edges.

19) Placement of PV Panels, 1st at the middle of the Left (and Right) span, then 2nd on to the outer

end, and 3rd on to the inner end of the PV Cables.

20) Tighten hex head bolts on the Clamps, both Mid and End.

21) Adjust Integral Tensioners as needed for balance and stability.


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Basis Assembly Sequence – Illustrated

1) Pier Blocks

2) Stanchions

3) Anchors and Cables

4) PV Hangers

5) PV Clamps (Mid and End)

6) PV Panels

7) Tensioning

8) Settling & Monitoring

Assembly Sequence

Standard (One Anchor per) End Cable Installation [See following drawing]

PV Hanger Installation [See following drawing]

PV Clamp Installation [See following drawings 1 and 2 of 2)


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33


34


35


36

PV Hanger upon initial installation; the PV panel rests on the arm, secured with the hook.

Conventional wrenches are used to secure the PV Clamp to the PV panel. End Clamp shown.


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Detail Assembly Procedures

NOTE: Step numbers correspond with the numbered pictures in the Pictorial Assembly Sequence

1) PLACE PIER BLOCKS, spaced at nominal span length; 8 feet minimum between rows.

2) SET END AND MID STANCHIONS onto cradles on the Pier Blocks.

3) SET EARTH ANCHORS, about 62 inches from the End Stanchions.

4) DIG OUT OBSTACLES IN PATH OF ANCHORS, if less than 12 inches deep, if necessary.

5) SCREW IN EARTH ANCHORS, using a ¾ inch All Thread Rod, either as a “T” or bar.

6) INSTALL PV/DOC AND END CABLES; initially tighten all Cable Clips.

7) HOOK PV CLAMPS ONTO PV CABLE, loosely and spaced appropriately.

8) PLACE NYLON SPACER ONTO CABLE BOLT.

9) PLACE NYLOK NUT ONTO CLAMP BOLT; tighten. [See 17]

10) LEVEL STANCHIONS BEFORE TENSIONING CABLES, via a spade shovel (recommended).

11) PLACE PV HANGERS ON UPPER PV CABLES, at mid PV Panel locations.

12) RUN CABLES THROUGH THE MID STANCHION HARDWARE and snug lag bolts, esp. to retain rods.

13) TIGHTEN TURNBUCKLES ON END CABLES, using two wrenches – using one as a lever.

14) GLUE CRADLES ON MID-STANCHION PIER BLOCKS, upon final leveling.

15) PLACE PV PANELS, initially resting on the PV Hangers, alternating placement left to right.

16) SECURE PV CLIPS (at top) ONTO PV HANGERS, using two wrenches.

17) ASSURE PV CLAMP BOLTS ARE TIGHT, with clamps placed at PV Panel edges, mid and end.

18) ROTATE END CLIP INTO CLAMPING POSITION.

19) TIGHTEN PV BOLT ON PV CLAMPS, with two wrenches.

20) DRILL AND INSTALL LAG BOLTS TO ALL CRADLES, both sides, on each stanchion.

21) ASSURE END CABLES ARE ATTACHED PROPERLY, with the Shoulder Bolts flush.

22) ASSURE PV/DOC CABLES ARE ATTACHED PROPERLY, tensioned to about 150 pounds.

23) PLACE COMBINER BOX NEAR (about 18 inches) END STANCHION, onto 4X4T post.

24) PLACE THROUGH (Junction) BOX NEAR (about 18 inches) END STANCHION, onto 4X4T post.

25) TIGHTEN ALL PV CLAMPING BOLTS (Mid and End).

26) INSTALL A SECOND CABLE CLIP ON THE UPPER PV CABLES, both ends.

27) INSTALL GROUNDING ROD, with copper cables to each PV Cable, on each row.

28) INSTALL EQUIPMENT GROUNDS, via (Tyco) lugs, to each PV Panel.

29) TIGHTEN PV/DOC CABLES, with two wrenches.

30) PLACE CROSS TIES and install pop rivets onto each end to secure.

31) PLACE OUTER CROSS TIE beyond (outside) the end clamps.

32) ADJUDGE (“eyeball”) OVERALL LEVEL AND PLUMB, and adjust as necessary – cradle bolts, etc.

Additional Notes: Assembly is both a logical and an intuitive process. Balancing, leveling, and tensioning

are iterative in nature, and should be done in modest increments during the assembly.


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Cable Tensioning (considering PV static weight)

Fv = W*S/2 [Force, vertical at the integral tensioner]

Fh = W/(8*h)*(S^2 – 4*h^2) [Force, horizontal at the integral tensioner]

where

W = Weight per unit length (pounds per foot) [0.11 lbs/foot for ¼” SS cable]

S = Cable length, under sag

h = Sag at middle span

Forces on the PV array at 30 degree tilt due to wind:

F(wind)v = 0.433*F(wind)

F(wind)h = 0.25*F(wind)

where

F(wind) = A*P*Cd; A = cross sectional area SF; P = 0.00256*V^2 (mph); Cd = 1.2 cylinder; 2 flat plate

A 60 mph wind exerts a total force (over the vertical cross sectional surface area of the PV array) of 864

pounds (assuming a Cd of 1.5 for the inclined surface). For comparison, a 90 mph wind exerts a

(horizontal) force of 1944 pounds over the same array. These forces translate to increase tension in the

PV cables and to an increased downward force at the integral tensioner.

Forces on the PV array with 10 inches of snow on panels:

Typical 125 SF total PV area of G1 array x 1/12 x 7.5 lbs/CF = 78 lbs (both spans); so, 40 lbs on one span

Generally, the tension of the PV cables increases by 50% with a foot of snow and doubles (increases

100%) in a 60 mph wind. At a very minimum, anchors must have a 2:1 margin for normal withstand of

typical weather-induced forces, while a 3:1 is recommended for extreme conditions. Note, if anchors

were to begin pull out in high winds, the static tension is reduced due to induced sag, thus, reducing the

pull out force. Maintenance is then needed after the wind event to restore normal static tension.


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Special Procedures

PV Panel Removal

Re-Tensioning

Disassembly

Inclement Weather Preparation

5 Maintenance

There are no scheduled maintenance requirements. Regular ongoing monitoring and inspection are

recommended, to assure cable tensions. As a history is achieved, inspection internals may be expanded,

if not eliminated.

To inspect: position and solidness of mid and end clamps on the PV Panels.

To check: tension in the PV, DOC (Opposing or “Damping”), and End Cables.

To check: plumb of the vertical posts of the End Stanchions.


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6 Design Science Plan for Tensioned Cable Systems

The idea of a Design Science is derived from R. Buckminster Fuller’s design science around the concept

of livingry, as opposed to weaponry, and his concept of ephemeralization – doing more with less. Much

of the 20th century has been used to devise “immer enzetslichere waffen” ever more terrorizing

weapons, and using much of the science and engineering talent of a few generations to serve the

national interest. We are seeing the benefit of seeing beyond that thinking, as we are utterly in need of

a philosophy of doing more with less and doing so with fairness to others and respect for the planet.

When students learn the basics of science, geometry, and engineering (problem solving), they are

empowering themselves. That power allows entry into the realm of creativity in the natural world,

which does obey inviolate laws of physics. A design science must respect the fundamental laws of

physics – gravity, forces, moments, strength of materials, etc. Like other science – biology, geology,

chemistry, and so on – research is always ongoing and we are always seeking…more data, more

knowledge, more understanding, and ultimately a positive advancement of one’s being in the real

world. We have no exact definition of this new Design Science applying tensioned cables to solve

problems in solar energy production, but we will let it evolve. We start with fundamental knowledge

and principles.

Mathematics

Engineering and Strength of Materials

Design

Innovation

TBD


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7 Certifications and Approvals

No certifications or approvals exist at this time, though they are anticipated in certain jurisdictions, such

as California. Local codes and regulations may apply. Some cities require a mechanical inspection of the

roof mounting system. Most counties do not require building permits for roof mount systems if overall

weight is under 5 pounds per square foot.

8 Warranty Information

A one year warranty on mounting kits for workmanship and performance is provided, with part

replacement upon verification of any problem. Metallurgical issues are anticipated, believed to be only

aesthetic in nature. All attempts have been made to secure quality metal and pre-fabricated parts.

Disclaimer of Liability

Olympic Energy Systems, Inc. does not guarantee the operational capability of the TCS mounting system

when the procedures and guidelines of this manual are not followed. Since compliance with this manual

and the included guidelines, recommendations, procedures, techniques, and methods is not

independently monitored by Olympic Energy Systems, Inc., Olympic Energy Systems, Inc. accepts no

liability for damage arising through improper use or incorrect installation, operation, or maintenance of

the TCS mounting system.


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9 Glossary of Terms

STANCHION – Structural Member that bears (compressive) loads. In the G1, the stanchion uses 4x4

Treated lumber and stainless steel Thrust Plates.

THRUST PLATE – Holds the Integral Tensioners and transfers the load from cables to the strength

members of the Stanchions.

INTEGRAL TENSIONER – Eye (or Shoulder) bolt connected to cables for in-line tensioning. In the G1,

integral tensioners are attached to the Thrust Plates.

PIER BLOCK – Concrete block with Cradle hardware (for 4x4 Treated) used to spread the load (weight of

Stanchions and PV Panels) over a larger area (than a mere 4x4 post footprint area).

TENSIONED CABLE SYSTEM (TCS) – Short for Tensioned Cable Solar Panel Mounting System. Any of a

variety of ways and means to mount solar panels using tensioned cables. Examples, the TCS R1 (roof)

and TCS G1 (ground); part of a design science, allowing for an evolution of designs and approaches.

PV HANGER – A mechanical device used to place (and mount) a PV panel onto the top set of PV Cables,

prior to clamping, to allow all PV panel weight to exert on the cable system before (final) clamping. In

the G1, one per panel, attached to the top PV Cable.

PV CABLE – The Cable (Wire Rope) actually supporting the PV panel; part of a Dual Opposing Cable pair

(for stability in wind, snow, etc.) The PV cable is otherwise known as the load cable.

DOC – Dual Opposing Catenary (DOC) Cables connected with Cross Ties that provide stability, especially

in winds opposing the weight of the PV panels. The DOC is otherwise known as the damping cable.

DOC CABLE – The underside cable of a Dual Opposing Catenary Cable pair; exploits the near catenary

shape of the top sagging cable and the inverse catenary of the opposing underside cable.

CROSS TIES – The series of connections (strap stainless steel) between the PV Cable and the DOC Cable

that allow opposing forces to be held by a near-catenary shape cable. Example, snow weight is

countered by the sag of the PV Cable, which the shape preserved with the Cross Ties. Wind loading

from behind the mounting system is countered by the DOC Cable on the upper span; winds from the

front are countered by the DOC Cable on the lower span.

MID CLAMP – A device for attaching two PV Panels to a PV Cable; allows for free hanging.

END CLAMP – A device for attaching the side of a PV Panels to a PV Cable; allows for free hanging. There

are left and right oriented clamps, depending on which end of the array is attached.


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Appendix

TBD

[May include: soil mechanics; solar insolation (by region) tables; comparisons with conventional

mounting systems, etc.]

Documents

Installation MANUAL - Olympic Energy Systems...Tensioned cables in roof mount systems (R í and R î) have a “hold down” role, with much of the panel ... holding up significant