Ground Mount Eco Series Installation Manual...Bottom Cap on Flange Type Ground Screw Bottom Cap on...

Ground Mount Eco Series

Installation Manual

of 17 Ground Mount Installation Manual

1.0 INTRODUCTION ................................................................................................................................................... 3

1.1 Useful Instructions .......................................................................................................................................... 3

1.2 The installer is solely responsible for: ............................................................................................................. 3

2.0 PREPARATION FOR INSTALLATION ...................................................................................................................... 4

2.1 Planning the installation.................................................................................................................................. 4

2.2 Safety first ....................................................................................................................................................... 4

2.3 Tools for installation ........................................................................................................................................ 4

2.4 Machinery for Installation ............................................................................................................................... 5

2.5 Base for the Ground Mount Structure ............................................................................................................ 5

3.0 INSTALLATION OF GROUND MOUNT ECO SERIES STRUCTURE ........................................................................... 8

3.1 Overview of ground mount Eco Series components....................................................................................... 8

3.1.1 Solar panel mounting parts ........................................................................................................................................ 8

3.1.2 Fastening Components and Recommended Torque Application ............................................................................... 8

3.1.3 Structure Mounting Parts ........................................................................................................................................... 8

3.2 Finished Structure ........................................................................................................................................... 9

3.3 Structure Mounting ....................................................................................................................................... 10

4.0 CONTACT DETAILS ............................................................................................................................................. 17


1.1 INTRODUCTION

1.1 Useful Instructions

Thank you for choosing Red Dot Rack (RDR) for your solar installation project. This installation manual describes how to assemble and install the Ground Mount Eco Series Structures produced by RDR. ALL RDR Ground Mount structures are compliant with the structural design requirements of Australian / New Zealand standard AS 1170, backed with a 12-year warranty. It is designed to be used with all small scale, large scale commercial, and utility scale solar PV farm installations for fast and simple installation to minimise labour time and costs. The components are supplied as pre-assembled parts and are made from the highest quality materials to provide the most durable structure in the industry, backed by the RDR leading 12-year warranty. RDR Ground Mount Eco Series Structure components include:

• Steel ground screws: foundation that is designed to be secure to the Front and Rear Legs. A hydraulic pile driver machine is used to drill them into the ground.

• Steel Front and Rear legs: designed with tube shape so that it can withstand with max wind speed of region D.

• Steel Truss and Batten Rails: designed with “Unistrut” channel so that they can be easily attached by channel nut

• End-clamps and Mid-clamps: used to hold the solar panels by the Ground Mount Structure. Hex screw, a standard drill bit tool, is required to attach them with the rails.

Please review this manual thoroughly before installing your Ground Mount Eco Series Structures. It contains important safety information and installation guidelines, which will vary with different site conditions and geographical locations. If you are unsure of anything, or would like any additional help in installation, please contact your nearest Red Dot Rack representative, listed at the back of this manual.

1.2 The installer is solely responsible for:

• Ensuring a safe working environment during all steps of installation of the system.

• Complying with all applicable local and national building and electrical installation standards.

• Ensuring only genuine RDR Ground Mount Eco Series Structure parts are used throughout the installation. Substitution of parts could lead to a failure in the Ground Mount Eco Series Structure, and void warranty.

• Verifying that other loading factors including water, ice, snow and seismic loads are fully compliant and do not affect the safety of the installation.

WARNING INSTALLATION OF RDR GROUND MOUNT ECO SERIES STRUCTURES IS INTENDED TO BE PERFORMED BY PROFESSIONALLY TRAINED INSTALLERS ONLY. ANY ATTEMPT TO INSTALL RDR GROUND MOUNT BUSGET SYSTEM STRUCTURES BY AN UNQUALIFIED INDIVIDUAL COULD RESULT IN INJURY OR DEATH


1.2 PREPARATION FOR INSTALLATION

2.1 Planning the installation

The RDR Ground Mount Eco Series Structures have been designed to be installed with a wide range of soil and geographical location conditions. The correct footing type, pole depth and spacing must be chosen to comply with the local wind and snow loading, soil conditions and building installation codes. Before commencing installation please ensure that you have all layout and structural diagrams and have fully read through and understood this installation manual. The RDR Ground Mount Eco Series Structures are designed for installation in soft or hard soil, which will determine the Ground Screw embedment depth. It is also able to be installed in Region-A to Region-D with different wind speeds (AS1170.2:2011) and this will determine the pole spacing distance. The structure can also be installed on high load capability concrete rooftops with modifications to the pole. The Red Dot Rack engineers or third party geotechnical analysis team would have pre-determined this design information for you at the time of the project design and engineering consultation.

2.2 Safety first As in all construction sites, workplace safety is the priority. Please wear and promote the following PPE items.

High visibility jacket Safety boots Hard hat Safety glasses Working gloves

2.3 Tools for installation

M12

5-meter tape measure

socket wrench

Rubber mallet

Socket T- wrench


2.4 Machinery for Installation

Additional machinery required for the installation depends on the footing type selected for the project. Ground Screw will require a hydraulic pile driver machine (as in the picture), fitted with a Red Dot Rack compatible driver head. Ballast concrete footings may require a forklift or pallet jack to transport and place heavy loads. The foundation type will be specified on the structural drawings.

2.5 Base for the Ground Mount Structure Based on the ground conditions and customer requirements, the base for the Ground Mount Structure can be selected. However, considering those conditions, the RDR team would have provided correct type of base by the time you start your installation. RDR provides,

• Open Tube Head Ground Screws, which can be directly connected to the legs of the structure,

• Flange Type Ground Screws, which are connected to legs of the structure using Bottom Caps, and

• Bottom Caps itself installed directly on concreate ballasts or install on Flange Type Ground Screws

Please see the provided figures for each type of base.

Part description

Steel Ground Screw - Open Tube Head

Steel Ground Screw - Flange Type

Bottom Cap


Ground Screw and Bottom Cap Position Marking

• Mark the opposite sides using a survey cam. • Stretch a nylon string between the first marking pair.

• Prepare a rod to mark the positions of the Ground Screws.

• Move the marking rod from one end to another and same thing is required for verifying the spacings

• Do the same for all marking pairs

Ground Screw (Open and Flange) Installation Using a pile driver ramming machine, fitted with a compatible driving head, drive each ground screw into the soil at marking points to the pre-determined depth as per the project specification. Space each driven post at the pre-determined distance apart, as per the project specification.


Alignment of Ground Screw The alignment of Ground Screw, both Vertical and Horizontal, can be set using one of the following two methods.

• Auto-Levelling and Alignment with laser guided system. This laser guided system is a feature of more advance pile driving machines, whereby an emitter on the pile driving machine pairs with a receiver placed at the far end of the row of piles. A signal is sent when alignment is reached.

• Manual string level and alignment system. This method applied in such condition when pile driving machine is not fitted with the laser guided system. A string line is required to be installed taught (without slack) at a level height across the distance of the Ground Screw to be installed. Note: take caution in the distances over which the string line is used, as the string may tend to dip under self-weight.

Bottom Cap Installation

Bottom Cap on Flange Type Ground Screw Bottom Cap on concrete ballast

• Bottom Cap on Flange Type Ground Screw: Place the Bottom Cap nicely on the Flange Type Ground

Screw and adjust it so that two screws (M12) can be inserted as in the above left figure. Secure the both M12x25 screws with torque application range from 28-30 Nm.

• Bottom Cap on concrete ballast: When Bottom Cap dirrectly install on concrete ballast, four M12x25 screws have to be used to provide the required strength to hold the structure. Place the Bottom Cap on the marked position and apply torque of 28-30 Nm to secure the screws.


1.3 INSTALLATION OF GROUND MOUNT ECO SERIES STRUCTURE

3.1 Overview of ground mount Eco Series components

3.1.1 Solar panel mounting parts

The following table shows the parts required for mounting the solar panels

Part description

Adjustable Mid Clamp Fixed End Clamp

3.1.2 Fastening Components and Recommended Torque Application

The RDR Ground Mount Eco Series Structures use SS-304 M8, M10 screw in various lengths, and SS A2-70 M12 Bolts in various lengths. The following is a recommendation for the torque application range of each component:

Bolt Diameter Material Torque Application Range

M8 Stainless Steel Grade: SS-304 8-10 Nm

M10 Stainless Steel Grade: SS-304 15-25 Nm

M12 Stainless Steel Grade: A2-70 28-30 Nm

3.1.3 Structure Mounting Parts

The following table shows the parts that are required for the Ground Mounting Eco Series Structure assembly.

Part description Galvanized Front Leg Piece, Oval End Tube

Galvanized Rear Leg Piece, Oval End Tube


Galvanised Truss Rail

Galvanised Batten Rail

Galvanized Brace Arm

Pivot Bracket Rail Connector Brace Arm Bracket Batten Rail Joiner Screw M12

3.2 Finished Structure

The following figure shows the finished structure which is assembled using the above components.


3.3 Structure Mounting

Step 1: Insert M12 x25 into Ground Screw

Turn the 3 Screw M12 x25 into ground screw (or Bottom Cap), make sure the screws do not over the hollow of ground screw (red circle).

Step-2: Insert Brace Arm Bracket into Rear Leg Insert the Brace arm bracket in to rear leg. Do not secure

Step 3: Install Front and Rear Legs into Ground Screw Insert the Front Leg and Rear Leg (included brace arm bracket) into ground screw and set the length

above ground screw (H1 and H2) with specified dimensions according the drawing of each project.


Secure the 3x M12x15 with torque application range from 28-30 Nm after setting H1 and H2

Stretch Nylon strings between both ends of Front and Rear Legs as guide lines for levelling other Front and Rear Legs in the row.

Level all the other legs according to the Nylon Wire height.

Nylone wire for levelling the front and rear leg

Step 4: Install Pivot Bracket into Front and Rear Legs

Each Front and Rear Leg requires a Pivot Bracket attached to it. The Pivot Bracket is attached to the upper (flat) end of the Front and Rear Legs and provides the main structural point of the Truss Rail.

Fasten the Pivot Bracket to the top of each Front and Rear Leg, but do not secure the screw.


Step 5: Truss Installation

Mount the Truss Rail into Pivot Bracket at locations specified in the drawing (check A1 and A2 lengths).

Measure the H4 and Angle that are specified by project’s drawing Secure the Pivot Bracket into Truss Rail. Secure the Pivot Bracket into Front and Rear Leg.

Follow the same steps to install the Truss Rail at the other end Stretch nylon strings between both ends of Truss Rails in the row as guide lines for levelling other

Truss Rails in row. Continue install other Truss Rails until finish the row.

Nylone wire for levelling the Truss Rail


Step 6: Installation Brace Arm into Bracket

Setting the location of Brace Arm Bracket above ground screw with H3 that is specified in the project drawing, then secure the screw to fix the brace arm bracket.

Install Brace Arm to Brace Arm Bracket and Pivot Bracket Then, install the Pivot Bracket (included Brace Arm) into Truss Rail


Step-7: Batten Rail Installation The Rails are supplied in pre-cut lengths. To connect two batten Rails together, use the Batten Rail Joiner. The Batten Rails are attached to the top of Truss Rails, with the Batten-Truss Connector. The RDR Ground Mounting Structure parts required:

• Batten Rail

• Batten Rail Joiner

• Batten –Truss Connector

Step 7.1: Joining the Batten Rails The Batten Rails are connected together by Batten Rail Joiner.

Use Wrench for Hex M8 to secure 2 x Screws. Continue join the Batten Rails until get the enough length specified in project’s drawing

Step 7.2: Attach the Batten Rails to Truss Rail

To fasten the Batten Rails to the Truss Rails, use the Batten –Truss Connector. The Spacing B1, B2 of Batten Rails are specified in project’s drawing. Attach and secure the screw M8 to connect Batten Rail to Truss Rail.


And now the RDR Ground Mounting Eco Series Structure is almost done and ready for the solar panels to be placed on it.

Step-8: Solar Panels Installation

Attach and fasten the solar panels to the structure in portrait configuration, located directly on top of the Batten Rails. The mounting holes of the solar panels should be placed right above the Batten Rails, or as recommended by the solar panel manufacturer. Once the solar panel is in the correct position, clamp the panel down to the structure using the Adjustable Mid Clamps and Fixed End Clamps. Be sure to use the Wrench to tighten the Hex Screw M8 of mid/end clamps.

The Solar panels are assembled to The Red Dot Rack Ground Mounting Structures 1 panel at a time. Use a suitable means to prevent the panels slipping from the frame during the installation. Once installed, the mounting clamps will hold the solar module panels in place. Until the clamps are securely installed, the solar panel module needs to be appropriately secured. For more information, please see the following figures.

1

WARNING ENSURE YOU FOLLOW ANY OF THE RECOMMENDATIONS AND INSTRUCTIONS OF THE SOLAR PANEL MODULE SUPPLIER IN HANDLING AND INSTALLING THE SOLAR PANEL MODULES. FOLLOW THE NEXT INSTRUCTIONS CAREFULLY. WHEN INSTALLING THE PANELS CORRECTLY USING THE RED DOT RACK GROUND MOUNTING STRUCTURE COMPONENTS, THE SOLAR PANEL MODULES WILL NOT BE DAMAGED.


2 3

Illustration of the finished Galvanized Steel Ground Mounting Structure, with the solar panels attached.

Step-9: Earthing Lug Installation The Solar panels is grounded by many methods. Though it is optional for customers, RDR wants to offer a quickly and stand earthing component which is attached to the Mid Clamp for grounding the solar panel.


1.4 CONTACT DETAILS

Head Office, Singapore Red Dot Rack Co., Ltd. 18 Boon Lay Way, Tradehub 21 #06-135 Singapore 609966 www.reddotrack.com [email protected]

Thank You

mailto:[email protected]

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