Sharp SRS Mounting System User Manual Download

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Solar Power System

Installation Manual

SHARP ELECTRONICS CORPORATION

SOLAR ENERGY SOLUTIONS GROUP • 5901 BOLSA AVENUE • HUNTINGTON BEACH, CALIFORNIA 92647

SRS Mounting System

Rectangular Modules

Version 2008.03.19

Summary of Contents for SRS Mounting System

Page 1: ...ar Power System Installation Manual SHARP ELECTRONICS CORPORATION SOLAR ENERGY SOLUTIONS GROUP 5901 BOLSA AVENUE HUNTINGTON BEACH CALIFORNIA 92647 SRS Mounting System Rectangular Modules Version 2008 03 19 ...

Page 2: ...uidelines This manual provides guidelines for installation but it does not guarantee the quality of installation work Please complete all work in a responsible and professional manner Electrical work should be performed by a qualified electrician For installation personnel The SRS mounting system has been load tested and verified by a Professional Engineer This information can be provided upon req...

Page 3: ...187u1 ND 187U1F module array layout dimensions 14 4 Parts 15 19 5 Points to Check Before Installation Work 19 20 6 Installation Work 21 44 6 1 Preparing shingle roof for installation 21 6 2 Checking layout 22 6 3 Installing the optional flashings 23 6 4 Installing standard slider assembly 24 6 5 Preparing tile roof installation 25 6 6 Checking layout 26 6 7 Installing tile slider assembly 27 30 6 ...

Page 4: ...d tools The solar modules or mounts may fall if the installation is not strong enough for example when parts are not tightened sufficiently Regardless of whether you are working on a new or existing roof never allow the sheathing to become wet Protect the sheathing from rain during the installation Failure to do so may cause leaks Always use the specified materials Use of other materials is danger...

Page 5: ... applicable Wiring methods should be in accordance with the NEC Install wires and cables with appropriate hardware in accordance with applicable electrical codes Protective earth grounding of the individual photovoltaic modules is achieved by securing the modules to the mounting frames The assembly instructions should be closely followed in order to ensure a reliable ground connection The framing ...

Page 6: ...ot cut or modify parts or rails 2 Work under dry conditions with dry tools 1 1 Cautions regarding installation of solar power systems 3 Do not stand or step on solar module 4 Do not install near flammable gases 5 Do not drop or allow objects to fall onto module 6 Completelycoversolarmodulewithopaquematerials when wiring to halt production of electricity 7 Keep the back side of solar module surface...

Page 7: ...foreuse alwaysinspectladdersandstepladders to makes sure they are in good condition 1 2 SRS MOUNTING SYSTEM Choose a safe spot to anchor ladders and stepladders Always work with a partner One person should hold the ladder steady Ladders from a first story roof to a second story roof are very dangerous Do not set up a ladder on a roof When there is no other choice straddle the ridge and lay down a ...

Page 8: ...d 2 Wiring the solar modules Never step or sit on the glass surface of the solar modules The glass may break Whenyouinstallthesolarmodulesontherail never allow an output cable to become caught between the rail and a module frame The solar modules generate electricity when exposed to sunlight take care not to short circuit the output cables The cables can become overheated and their cable sheaths c...

Page 9: ... illustrations detail typical roof construction as well as old roof problems Inspection of the roof support system This may require access to the attic Check that all rafters trusses and other materials are in good condition Check for indication of previous water leaks Measure the spacing of the rafters or trusses to confirm the dimensions and prepare for the system layout Determine the location o...

Page 10: ... condition Broken shingles and sagging roof Damaged shingles Example ROOF CONSTRUCTION Asphalt shingles Roofing felt Roofing deck Facia board Rafters Rake Ridge 1 0 2 Points to Check when Selecting the Installation Location ...

Page 11: ...d of 30 lbs per square foot or 45 lbs per square foot The system has been load tested by Sharp to 50 PSF Building departments often require a design safety factor of 1 5 or greater for structures The maximum structural loading listed in this guide does not include an added safety factor 10 To achieve maximum load capacity use at least the same number of sliders as modules on each rail BASIC Wind s...

Page 12: ...ocate in a corrosion prone area 4 The array must be installed at least 16 away from the eave of the roof and 12 from the sides of the roof This border will enhance the wind load resistance of the system Measure the perimeter of the roof surface where the array will be installed 16 min 12 min 12 min 12 min SOLAR MODULES CAN NOT BE LOCATED IN SHADED AREA 5 The output of a series string of solar modu...

Page 13: ...10 5 percent of Pmax under standard test conditions irradiance of 100 mW cm2 AM 1 5 spectrum and a cell temperature of 25 C 77 F Under normal conditions a photovoltaic module may experience conditions that cause more current and or voltage than reported at Standard Test Conditions Accordingly the values of Isc and Voc marked on UL Listed modules should be multiplied by a factor of 1 25 when determ...

Page 14: ...l fit on the installation location Maximum module layout shown is 16 wide x 6 tall Contact Sharp for other configurations ND 187U1 ND 187U1F ND 167U1Y 39 1 8 78 1 4 117 3 8 156 1 2 195 5 8 234 3 4 273 7 8 313 352 1 8 391 1 4 430 3 8 469 1 2 508 5 8 547 3 4 586 7 8 626 58 7 8 52 7 16 Eave cover 1 5 8 117 3 4 104 15 16 176 5 8 157 3 8 235 1 2 157 3 8 294 3 8 209 13 16 Ridge cover 1 5 8 353 1 4 262 1...

Page 15: ...ide cover screw shown appx size Dimensions M4 x 12 mm Material Anti corrosion coated steel Aluminum Stainless steel Part No AA801 AA802 AA803 AA804 Model name Rail 1 in 1 Rail 2 in 1 Rail 3 in 1 Rail 4 in 1 Dimensions Length 35 98 Length 75 12 Length 114 25 Length 153 39 Material Anti corrosion coated steel Part No AA805 AB801 AB802 AB803 Model name Rail 1 5 in 1 Front cover Front cover half size ...

Page 16: ... AK111 AE104 AE102 Model name Tile roof slider Support AL plate Tile roof stand off Tile roof slider bracket Material Anti corrosion coated steel Aluminum Anti corrosion coated steel Anti corrosion coated steel Part No XA27 XA02 Model name Support AL screw 5 5 x 35 shown appx size Standard slider mounting screw 5 5 x 80 shown appx size Material Stainless steel Part No XA50 Model name Tile roof sta...

Page 17: ...acket Dimensions 11 x 2 x 1 14 x 10 x 1 25 Material Anti corrosion coated steel Anti corrosion coated steel Part No AE107 XA02 Model name Silicone caulking Standard slider mounting screw 5 5 x 80 shown appx size Material Silicone Stainless steel Part No XA58 Model name Standard slider mounting screw w flashing 5 5 x 110 shown appx size Material Stainless steel 4 pARTs ...

Page 18: ...name 0 1 shim 0 4 shim M8 Bolt 30 shown appx size Dimensions M8 x 30 mm Material Anti corrosion coated steel Stainless Steel Part No XA54 XA55 Model name M8 Bolt 40 shown appx size M8 Bolt 50 shown appx size Dimensions M8 x 40 mm M8 x 50 mm Material Stainless Steel Part No XA56 XA57 Model name M8 Bolt 60 shown appx size M8 Bolt 70 shown appx size Dimensions M8 x 60 mm M8 x 70 mm Material Stainless...

Page 19: ... the roof is wet There is a danger of slipping falling and shock CAUTION Never step or sit on the glass surface of the solar modules The glass may break Do not twist the solar modules when you mount them twisting should not exceed 0 1 per 4 Failures and damage can result When you mount the solar modules on the rail never allow an output cable to become caught between the rail and a module frame Sh...

Page 20: ...an s pliers Wire cutters Hammer Chisel Crimping tool Knife Tape measure Extension cord Chalk line Gloves safety helmet Rope Tool belt Ladders Safety Harness Safety glasses Air mask Ratchet Wrench 13 mm 8 mm Measurement Compass Calculator Solar insolation meter Digital multimeter 5 Points to Check Before Installation Work ...

Page 21: ...om edge of the slider feet Note This line needs to be 0 22 5 5 mm away from the nearest front edge of shingles 4 Measure up from chalk line 0 8 20 mm and snap a new chalk line This marks the location of the bottom edges of the modules 5 Measure up from the module chalk line to the desired module height to form the array Snap horizontal lines at the measured locations for each row of rail 6 Mark an...

Page 22: ...ail 5 Iftheseoverlaporseemtooclose shiftrailshorizontally or move sliders to next rafter or remove splices to switch the long and short rails to opposite sides Reattach splices after rails are switched and recheck for overlap CAUTION The maximum module over hang from the slider to the edge of the array is 16 2 in 1 rail Rail splice Eave 16 max from the slider to the edge of the array Sliders not t...

Page 23: ...slider feet layout line 2 Dry fit the flashing in the location marked for installation Use a utility knife to cut the surrounding shingles to assure a flush and water resistant fit Install flashing over a layer of shingles to insure water resistance Front edge aligns with slider feet layout line Center mark aligns with center line of rafters Mark aligns with bottom edge of the bottom row of module...

Page 24: ...on the slider that prevent the standard slider bottom bracket from falling out Place the slider assembly in the measured location and install the self drilling screws at the upper and lower holes CAUTION The arrow on the standard slider assembly should point to the eave 3 Remove any debris and press the slider assembly into place Site window should align with the front edge of the shingles site wi...

Page 25: ...es install the next rails 3 courses higher than previous rail When using 187 Watt modules install the next rails 4 courses higher than previous rail 4 Measure up from chalk line 1 and snap a new chalk line This marks the location of the bottom edges of the modules 5 Measure up from the module chalk line to the desired module length to form the array Snap horizontal lines at the measured locations ...

Page 26: ... splices Rail splice 2 in 1 rail 5 Iftheseoverlaporseemtooclose shiftrailshorizontally or move sliders to next rafter or remove splices to switch the long and short rails to opposite sides Reattach splices after rails are switched and recheck for overlap CAUTION The maximum distance from the slider to the edge of the array is 16 2 in 1 rail Rail splice Eave 16 max from the slider to the edge of th...

Page 27: ...so that each slider is located in the valley of the tile Rafter chalk line Array horizontal chalk line 2 Number two tiles one above the other The lower tile will be removed to install the aluminum support plate Rafter chalk line Tile to remove Number the tiles so you can replace them in the original positions 3 Mark the edge of the upper tile on the lower tile to insure proper alignment upon assem...

Page 28: ... tile dust with a vacuum cleaner or brush pan CAUTION Drill holes on the ground for safety reason 7 Locatetherafterandplacethealuminumsupportplate on the deck Install two 80 mm screws XA02 through the plate spaced 5 apart into the rafter Install four 35 mm screws XA27 through the plate and into the deck The screws should be spaced equally along the upper and lower edges of the plate Support AL scr...

Page 29: ...g paper to expose sticky side Adhere the sticky side of the butyl pad to bottom side of tile 9 Inject Sharp supplied silicone caulk AE107 into the holes to form a dome The dimensions of the dome are 0 75 in height and 1 5 in diameter Fill the hole with caulk Silicone caulk Bottom butyl pad Tile CORRECT WRONG 10 Insert 2 top butyl pads onto the tile standoff legs Top butyl pad AE106 Remove paper ba...

Page 30: ...of stand off screw XA50 13 Push the top butyl pad into the silicone dome Make sure that the silicone caulk forms a bead around the butyl pad Support AL plate AK111 Bottom butyl pad AE105 Top butyl pad AE106 Tile roof stand off AE104 Notice Butyl pads should be pushed down after sliders are secured to stand off with two 135 mm screws XA50 Silicone Silicone CORRECT WRONG 14 Insert the roof tile slid...

Page 31: ...path Thiscanbeachievedbyinstallinggroundinghardware on either end of bottom rails 1 Install outdoor rated ground lugs or ring terminals with ground wire per above drawings Use the marked ground hole on either end of the rail 2 Connect a minimum 10 AWG solid conductor copper ground wire to the ground lug or ring terminal 3 Connect the end of the equipment grounding conductor in the array junction b...

Page 32: ... Insert M8 bolts XA52 through dock washer AD804 and fasten to standard slider bottom bracket 0 1 shim 0 4 shim 0 1 shim 0 4 shim 4 Use shim kit to level the height of the rail on the roof Place shim between rail and standard slider top bracket Slide the shim into the bolt so that it is fully engaged Note There are two types of leveling shims 0 1 AK113 and 0 4 AK114 You will need to use bolts of di...

Page 33: ...ng clip 3 Insert an M8 bolt through the clip and rail and secure to threaded tab AD105 Threaded tab Module mounting clip M8x20 bolt CAUTION Bolt Tightening Instructions Begin tightening bolts by hand After 5 turns by hand use a socket driver to finish tightening The proper torque is SI units 12 5 Nm USA units 9 3 ft lb Protective earth grounding of the individual photovoltaic modules is achieved b...

Page 34: ... the high points of the rail EAVE 2 Lift the solar module at side facing the ridge of the roof The solar module will slide forward slightly and will engage the locking clip as shown 3 Push the solar module forward and rotate down to fully engage the locking clip as shown 4 Installallofthesolarmodules in the row using the same procedure 6 Installation Work EAVE EAVE 3 4 ...

Page 35: ...angular module Secure each clip with an M8 bolt and AD105 threaded tab Continue this process until all rows have been installed EAVE EAVE Rail Module mounting clip Previous row of solar modules 6 12 InstallING top cover 1 Place rail cover at an angle to engage the rail clip 2 Rotate the rail cover to fully engage the rail clip Side cover screw 3 Insert the screw into the threaded tap and screw int...

Page 36: ...Push in all the way Module output cable negative Waterproof connector CAUTION Be sure to always push the connectors all the way in Loose connections can result in heat burns and other damage 3 On the first solar module connect the positive home run cable to the positive array output cable and connect the negative cable to the positive cable of the second solar module On the second solar module con...

Page 37: ...der rail and snap bar into rail as shown above 6 If the array cables stretch between rows connect by running them underneath the rail WARNING Protect the terminals of the array output extension cables by covering them with insulating tape High voltage is generated between output cables whenever sunlight strikes a solar power array There is a danger of shock 7 Tape the output cables for each string...

Page 38: ...mns Solar module connections example 4 rows 4 columns each string has 8 modules connected in series Series connection String 1 String 1 String 2 String 2 String output cable Solar module Series connection String 1 String 1 String 2 String 2 String 3 String 3 String output cable Solar module 6 Installation Work 3 8 ...

Page 39: ...output cable connected to the 11th module and the positive array output cable connected to the 1st solar module Solar modules 1 to 11 Digital tester Black array output cable 1 2 3 4 5 6 7 8 negative positive White array output cable 9 10 11 The voltage will vary depending on the amount of sunlight but it should measure about 360 VDC Be careful of shock 3 Check the measurements Multiply the value m...

Page 40: ...installation There are no express warranties except as listed above THE DURATION OF ANY IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY IS LIMITED TO THE DURATION OF THE EXPRESS WARRANTY HEREIN THE WARRANTIES DESCRIBED HEREIN SHALL BE THE SOLE AND EXCLUSIVE WARRANTIES GRANTED BY SHARP AND SHALL BE THE SOLE AND EXCLUSIVE REMEDY AVAILABLE TO THE FIRST CONSUMER PURCHASER CORRECTI...

Page 41: ...NOTES ...

Page 42: ...SHARP ELECTRONICS CORPORATION SOLAR ENERGY SOLUTIONS GROUP 5901 BOLSA AVENUE HUNTINGTON BEACH CALIFORNIA 92647 SESG SRS 01 29 2008 ...

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