Shark Series Installation Manual - Rack 10 Solar...2015/09/03 · Shark Series Installation Manual...

Rack 10 Solar, LLC 35091 Paxson Road Round Hill, VA 20141

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Version 1.5

Shark Series Installation Manual


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Version 1.5 P a g e | 2

TABLE OF CONTENTS

1.0 INTRODUCTION 4

2.0 PRODUCT OVERVIEW 4

3.0 TECHNICAL SPECS. 4

4.0 INSTALLER RESPONSIBILITY 5

5.0 SITE SELECTION 5

6.0 MATERIALS AND TOOLS REQUIRED 6

7.0 COMPONENT LIST 7

8.0 ASSEMBLY AND INSTALLATION INSTRUCTIONS 11

9.0 MAINTENANCE 21

10.0 APPENDIX A 22

Ph: 703

WARNING

The Rack 10™ mounting system is engineered and tested to withstaproperly. Failure to install properly may decrease the performance of the installation

SAFETY

All regional safety requirements should be followed when installing

equipment/tools should be properly maintained and inspected prior to use. This installation manual

is intended for use by professional installers with a working knowledge of construction principles.


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engineered and tested to withstand specifications when installed properly. Failure to install properly may decrease the performance of the installation or void the warranty

All regional safety requirements should be followed when installing Rack 10 mounting systems

properly maintained and inspected prior to use. This installation manual



when installed or void the warranty.

Rack 10 mounting systems. All

properly maintained and inspected prior to use. This installation manual



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1.0 Introduction The purpose of this document is to provide instructions on how to properly install Rack 10™ Solar Shark Series mounting products.

2.0 Product Overview Rack 10 Solar™ offers a low profile easy to install ballasted solar mounting system to be used on the ground or on flat roofs. All components are made from marine grade aluminum & stainless steel. Components of Rack 10 Solar™ are the following: Ballast Pan Spacer Bar Grounding top clamp Hardware Features of the technologically advanced Rack 10 Solar™ system are:

• Evenly distributes weight across large surface area. • Built in wind deflector keeps ballasting weight to a minimum, as low as 3psf. • Just 3 components per PV module:

(1) Rack10™ ballast pan (1) spacer bar (1) grounding top clamp

• Standard module angles: 0, 5, 7.5 and 10 degrees.

3.0 Technical Specs. All materials are made from non-corrosive materials, 18-8 stainless steel or 5052 H32 aluminum, with a product warranty of fifteen (15) years


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4.0 Installer Responsibility

The installer is responsible for the following:

• Complying with all applicable local or national codes including any that may supersede the relevant requirements stated in this manual

• Ensuring that the Rack 10 Solar™ system components are appropriate for the particular installation and the installation environment

• Ensuring that the selected structure can support the mounting system under actual environmental loading conditions

• Using only Rack 10 Solar™parts. Substitution parts may void the warranty • Ensuring safe installation of all electrical aspects of the Solar PV System • Ensuring the installation shall be conducted by qualified service personnel only

WARNINGS

• Ensuring that the PV modules for which the rack was designed are in fact the PV modules being

used in the array assembly. Note: In the event that the PV modules on site and intended for installation are different than the design modules, immediately contact Rack 10 to verify that the geometry of the different modules can be safely installed with the supplied rack. Installation of geometrically incompatible modules with the rack may cause product failure and may prohibit safe and proper support of the modules.

• Cutting or bending of the pans without specific written authorization from the manufacturer may cause product failure and will void the racking warranty.

• If the roof slope exceeds 2.5% in any direction and it was not noted on the racking drawings, verify with Rack 10 that the excessive sloped area is suitable for rack installation without any supplemental sliding restraints beyond normal ballasting. If supplemental sliding restraints are required and were not part of the original design, it will be necessary to update the rack design and the Contractor will need to order parts deemed appropriate and have them installed pursuant to updated assembly drawings.

5.0 Site Selection Proper preparation of the ground, or building rooftop must be ensured for a well-performing system to be installed.

For ground mount applications, the Rack 10 Solar™ system will typically be mounted on a flat, or slightly graded, surface facing South. For rooftop mount applications, the Rack 10 Solar™ system must be mounted on a clean surface that passed inspection for structural support, and can withstand the additional pv array load. Roof manufacturer shall dictate the use & type of slip sheets.


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General guidelines include: Choose a clear area free of shading Prepare a well-drained pad of no more than five (5) degree slope west to east and zero (0) degrees north to south Suggested four (4) foot border surrounding array

6.0 Materials and Tools Required

The following tools are required for the installation of the Rack 10™ Shark Series system:

• Open end, Box Wrench (7/16" size) • Socket Wrench with 7/16" Deep Socket • Torque wrench: required settings = 10ft. lbs & 12ft. lbs • String line • Concrete or stone ballast (project specific wind load analysis shall be used to determine minimum

weight requirements)


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7.0 Component List

The Rack 10™ Shark series system contains the following parts: Ballast Pans (Full Pan & South Pan) Ballast Pan Spacer Bar Grounding Top Clamps Alignment Jigs 18-8 Stainless Steel Hardware (1/4” wax coated serrated flange nut, 1/4-20 x5/8” serrated flange screw, 1/4-20x3” serrated flange screw)

Full Pan South Pan


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Ballast Pan Spacer Bar


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End Clamp


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Mid Clamp


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8.0 Assembly and Installation Instructions

Delivered Product


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Step 1: Install Rack 10™ South Pans A. Measure the footprint of the array according to the PV Layout design documents, and find the

edges/corners of the array

B. Strike a straight East to West reference line at the south edge for placement of the south edge ballast

pans

C. Place approved slip sheet material under each pan location. Please note that slip sheet material may

be longer than ballast pans due to ballast block overhang.

D. Position and install South Pans on the East/West reference line with the 'jaw' feature facing north.

• Pins in the setup jig fit into the ballast pans’ pre-punched bolt holes, aligning the pans relative to eachother.

• East/West spacing between ballast pans is determined by the included setup jig.

• Aligning the pans to be square to each other is determined by the included setup jig.

• If seismic bracing is part of the design, the seismic bracing and stanchions would be bolted into place in

accordance with the design drawings at this time.

Setup Jig Seismic bracing, if required

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Step 2: Install Rack 10™ Ballast Pan Spacer Bar &

Install the Spacer Bar to the pans using the 1/4should be inserted through the outermost holes on the Spacer Bar (see figure Bar is installed in the center of the elevated flanges of the Torque the bolt to 12 ft.lbs. Installers have the option to slide pans located on the east & west edges of the array in towards the center of the array to increase the walking isle beside the PV array. See photo on page 15.


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Ballast Pan Spacer Bar & Full Pans

Install the Spacer Bar to the pans using the 1/4-20 x 5/8” stainless flange head bolt. should be inserted through the outermost holes on the Spacer Bar (see figure below

elevated flanges of the pans, where the threaded PEM nuts are.

e the option to slide pans located on the east & west edges of the array in towards the center of the array to increase the walking isle beside the PV array. See photo on page 15.


20 x 5/8” stainless flange head bolt. The bolts below). The Spacer

pans, where the threaded PEM nuts are.

e the option to slide pans located on the east & west edges of the array in towards the center of the array to increase the walking isle beside the PV array. See photo on page 15.


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Alternate Edge Pan Mounting Locations


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Step 4: Install Ballast The pans should be filled with (1) ballast block of concrete pavers according to site-specific design. Install the remaining ballast blocks after PV modules are installed (except on zero tilt systems, as all block needs to be installed in the zero tilt pans before the modules are installed).

Step 5: Install Home Run Wiring Series string home run wires can be installed north/south in conduit through the pans, or east/west in the cable ties, or zip-tied to the slots on the ballast pan.


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Step 5: Install PV modules

Install the PV modules in a landscape orientation. Slide the south edge of the pv module into the 'jaw' of the ballast pan. The pv module will be snug between the spacer bars. Ensure the pv module sits on the pan, not the spacer bar, and the pv module is square and flush in the ‘jaw’, as this feature of the mounting system is responsible for keeping the pv module in place (there is no south edge clamp). Connect pv wires to the adjacent PV module, and then rest the north edge of the pv module on the high edge of the northern ballast pan (see figure below).


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Step 6: Install top clamps

Install the top clamps with the ¼-20x3” serrated bolt through the inboard hole at the high side of the spacer bar, and torque the 1/4-20x3" bolt to 10 ft.-lbs. Mid clamps are situated between modules, while the edge clamp is at the ends of the row only (see figures below).

The modules and pans are all electrically bonded together, left to right and front to back to form one single structure. Maximum ampacity for each sub-array shall be 300A. Each sub-array needs to be properly grounded from ANY single point on that sub-array to an appropriate grounding source. Typical grounding points include use of a suitable grounding lug on a module and suitably sized and type of grounding wire.**Please confirm with an electrician, as this is their responsibility**

Mid Clamp

End Clamp


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2 Note use of integrated conduit support holes

9.0 Maintenance

1. Rack 10 Solar recommends a yearly inspection of all PV systems performed by an installer. Special attention shall be paid to loose or corroded electrical or mechanical connections and verification of proper grounding.

2. The installer shall adequately spot check the torque of all the fasteners. 3. In the unusual event that a PV module or racking component must be replaced or re-

torqued, proceed with the same care as during the initial installation. 4. The installer shall also verify that all ballast blocks are: a. free from damage or degradation b. properly positioned in the pans c. installed according to the plans and calculations of the project

1 Use of the integrated wire tie slots to hold a conduit support


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10.0 Appendix A

A.1 The PV racking’s geometry can be discerned from the product’s code as follows:

L-T- PW-J

Where: L = F for Full Pan or S for South Pan T = Tilt angle, degrees PW = Ballast pan width, north to south, inches J = Jaw depth = PV module frame depth, inches A.2 Disassembly and Reassembly. In the event that the array needs to be moved, it may be disassembled. If the array is re-assembled, in order to assure that the integrated grounding of the racking remains intact, all serrated nuts, bolts and clamps must be replaced with new ones. A.3 Pan layout sequence PV Module Rack 10 Pan

Shark Series Installation Manual - Rack 10 Solar...2015/09/03 · Shark Series Installation Manual...

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