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Ecolibrium Solar EcoX, Installation Manual

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Ecolibrium Solar EcoX Installation Manual Download Page 37

Appendix A: How to replace the Clamp Assembly with a Coupling

This procedure is 
used only in those 

situations wherein 
adjusting Attachments 
(Step 8e), fails to resolve 
interference issues 
between an Attachment 
and a Coupling. A 
common example of this 
is shown at left when a 
rafter falls where two 
modules meet.

To ensure proper 
electrical bonding 

install the modified 
Coupling  within the 
allowable left/right 
limits. The following 
page demonstrates the 
maximum allowable 
range of positions 
between the Coupling 
and Module Frame(s). 
Use the Alignment 
Marks and align to the 
Module Frame. Any less 
overlap inhibits proper 
bonding and may not 
properly support 
components.

Remove the Glider and 
Clamp assembly from 
the Base. Next, remove 
the Upper and Lower 
Clamps from the Glider 
by removing the Strut 
Bolt and Strut Nut.
Position the Coupling 
onto the Glider and re-
install the Strut Bolt and 
Strut Nut. Return the 
Glider to its original 
position on the Base. 
Align the Glider and 
Coupling to the Modules 
as described in sections 
8, 9, and A-2. Tighten 
and torque the Strut 
Bolt and Coupling Clamp 
to 14 ft-lbs.

Rafter happens 

to fall where two 

Modules meet

Attachment

mounted to rafter. 

Clamp Assembly 

must be replaced 

with Coupling

Module

Module

Skirt

Skirt

Strut Bolt

Coupling

Clamp Assembly

Glider

O-ring

Strut Nut

This situation requires a Coupling:

When a Rafter falls where two Modules meet, the Clamp 
Assembly must be removed and replaced with a Coupling.

Swap Clamp Assembly for Coupling:

Disassemble and reassemble with Coupling. Reuse Strut Bolt, 
Glider, O-ring and Strut Nut

A-1

A1. Disassemble Clamp Assembly and Rebuild using a Coupling

EcoX Gen2 Installation Guide, Rev 1.11

Summary of Contents for EcoX

Page 1: ...EcoX Gen2 Installation Guide Rev 1 11 Installation Guide Gen2 ...

Page 2: ...et 10 Install the Clamp Assemblies 11 Level and Align the Clamp Assemblies on Southern Row 12 Install Skirts on Downhill Row 14 Install Modules 17 Level the Modules 21 Grounding and Bonding overview 22 Appendix A How to Replace the Clamp Assembly with a Coupling A 1 Appendix B Thermal Expansion B 1 Appendix C Service and Maintenance C 1 Appendix D Modules Evaluated as part of EcoX UL 2703 Certific...

Page 3: ...of this guide on the job site at all times and contact Ecolibrium Solar with any installation questions related to EcoX Please note the following warnings when installing EcoX l EcoX Bonding Clip may have sharp edges l EcoX components fit together tightly and could cause pinch injuries l EcoX components may be hot to the touch if left in the sun Please follow the safety requirements below when ins...

Page 4: ...y Below is an example of the label http ecox estimator ecolibriumsolar com EcoX General Application Notes System Design and Span Requirements EcoX is designed to flush mount photovoltaic modules on pitched roofs as described in this guide The span between attachment locations depends on the module the site conditions and the system layout Site Specific System Design The EcoX Estimator is a powerfu...

Page 5: ...equirements 2015 October 1 4 Updated for 32mm Modules and Uphill Bonding Clip 2016 January 1 5 Updated bonding lug instruction 2016 March 1 6 Updated for membrane roof and additional approved modules 2016 December 1 7 Updated Appendix D with additional UL 2703 qualified modules 2017 September 1 8 Updated Appendix D 2017 October 1 9 Added Modules to Appendix D 2017 November 1 10 Added Modules to Ap...

Page 6: ...lled Bond Clip bonds Skirt to Attachment Kit on south row and Module to Attachment Kit on subsequent rows l l l l l The Attachment Kit is secured to the roof and supports the array via the Clamp Assembly Its features include Grooves along sides of Base are Dovetail Engagements which provide adjustability of the Clamp Assembly in height and uphill downhill directions Base is attached via a single L...

Page 7: ...ounts a micro inverter or power optimizer to the Module l The serrated teeth ensure a secure connection to the module l The Power Accessory Bracket bonds the micro inverter or power optimizer to the Module Torque Spec 14 ft lbs The Junction Box Bracket mounts to the Base and acts as a support for a Junction Box l Can be installed to any base l Can be installed before or after modules are installed...

Page 8: ...lamps and Couplings on uphill side of Modules 9 Level the row of Modules 10 Repeat Module install on subsequent rows 11 Install additional Bonding Clips at one end of each row to complete row to row bonding Required Tools Tape Measure Chalk Line Hammer Drill with 3 16 Bit Flat Roofing Bar Impact Driver 1 2 Socket String Line Torque Wrench Chalk l l l l l l l l l l Overview of Components Note Rooft...

Page 9: ... 3 4 gap between Modules The following page continues this layout and illustrates a finished rooftop layout l l Knowing where the Modules intersect will identify potential interferences between Attachments and Couplers Most AHJ s require a roof setback per their local fire code requirements Make sure that the required setback is observed when marking the footprint of the array 1a Mark the Four Cor...

Page 10: ...g the attachment locations make the downhill leg of the mark long enough to be visible from the downhill edge of the Flashing when the Flashing is in its installed position This mark will accelerate the Flashing installation by quick alignment of the Flashing to the mark 1b Snapping Chalk Lines and Marking Attachment Locations Corners of Array Make these marks extra long downhill See Roof Structur...

Page 11: ...to mount micro inverters or power optimizers to the modules 4 Prepare modules on the ground for easy wiring on the roof 2a Wire Management Position Leads install Clips 2 Prepare the Modules Before moving them to rooftop Position and attach Microinverters or Optimizers Remove their provided identification stickers and place them on the array map Use a marker and label each unit for easy to identifi...

Page 12: ... an example wire layout to illustrate typical wire management 3a Suggested Routing and use of Clips 3 The Basics on Wire Management Positive Home Run Negative Home Run 7 of 31 EcoX Gen2 Installation Guide Rev 1 11 ...

Page 13: ...oned Incorrectly Positioned Correctly Acceptable when necessary Position 2 1 2 4 Install Attachments to Roof 4b Drill 3 16 pilot hole 4c Apply Caulk to Flashing At the attachment locations drill a 3 16 piolt hole at a sufficient depth to fully secure the Lag Screw and Flashing to roof Prior to installing Flashing apply caulk in hole as an added sealant against moisture Seal any holes that missed a...

Page 14: ...ingles The bottom or downslope edge of the Flashing must not extend beyond the course of Shingles that it s attached to 4d Place Flashing 4 Install Attachments onto Roof cont Slide Flashing under uphill course of Shingles Use Flat Roofing Bar to lift uphill Shingles Align with Pilot Hole Chalk Line Lag Screw with Sealing Washer If needed Notch shingles to clear Base Base 4e Attach Base Base can be...

Page 15: ... be anywhere within this range Junction Box The Junction Box can be secured to the Bracket with Self Drilling Screws or by utilizing the Universal Mounting Slots along with appropriate attaching hardware The Junction Box Bracket is attached to the Base with Self Drilling Screws Select one of the previously installed Bases in a location suitable for mounting the Junction Box and install the Bracket...

Page 16: ...ion Middle Position start here Lowest Position Dovetailed Engagements change elevation in 1 4 increments Glider Align Highest setting Mark of Glider to top of Base Align Middle setting Mark of Glider to top of Base Align Lowest setting Mark of Glider to top of Base 1 range of adjustment 1 4 increments between High Low positions Clamp Assembly includes Glider Base 6b Install the Clamp Assemblies Gl...

Page 17: ...s Leaf Spring Channels 6 Install Clamp Assemblies cont A String Line is used to level and align Clamp Assemblies on the first downhill row only The body of the Glider includes one String Groove specifically designed to assist with this process Run and secure the String Line between the two outermost left right Clamp Assemblies Place String on the top String Grooves pulling it taught and securing i...

Page 18: ...Line Solution Raise Glider one Dovetail Engagement 1 4 to align Top Groove of Glider with String Base String Groove Top Groove Uphill Downhill Adjustments Height Adjustments String Line Gap Problem Gap too large between String Line and Glider Solution sliding Glider Toward String leaving a gap of 1 16 or less Reduce gap by String Line 13 of 31 EcoX Gen2 Installation Guide Rev 1 11 ...

Page 19: ... table The Skirt type is stamped on the inside face of Skirt Skirts must be installed in the correct dovetail engagement Skirt to Clamp to match the Module in use Once installed the Skirt sets the Upper Clamp position matching it to the Module thickness Metric Inches approx 33mm 1 5 16 35mm 32mm 1 3 8 1 1 2 40mm 50mm 2 1 5 8 55mm 1 11 16 Module Thickness Skirt must be installed in lowest position ...

Page 20: ... positions The upper position is used on 40 50mm Modules while the lower position is used on 32 33 35 45mm Modules Torque to 14 ft lbs 40 50mm use upper position shown 32 33 35 45mm use lower position Coupling centered over Skirt Joint is ideal Position Obstacle Attachment requires Coupling to be offset from center Offset is acceptable but within limits 4 Butt Skirt up against previously installed...

Page 21: ...ation to the Skirt See the second example at left Problem Clamp Assembly prevents proper positioning of Coupling Solution Rotate the Base and reposition the Clamp Assembly Clamp Assembly presents an obstacle Rotated Base allows movement of Clamp Assembly 8e Working around Obstacles Skirt Joint Coupling cannot be properly positioned it needs to shift about 1 2 to the left Coupling can now shift int...

Page 22: ...that the Module Frame has fully seated into against the Clamps and Couplers of the Skirt Row Place Module on tongues of the Lower Clamps and Coupling Rest Module on uphill Base Pivot Module downward while pushing it into the Skirt Row Clamp Assembly 1 1 2 2 3 3 Uphill Base Skirt Row Base Clamp Assembly m odule starting position module resting position View looking from left edge 4 Ensure that Modu...

Page 23: ...en them Set the gap by the alignment marks on the Skirt row Coupling s and aligning the Module frames to these marks As each row of Modules is installed complete all wiring connections and verify that all wire management clips and wires are properly arranged and off the rooftop before proceeding to the next row of Modules Wiring Install home runs or trunk cable if necessary as each row of modules ...

Page 24: ...loose while you position the remaining Clamps and install the Couplings 9c Install the Uphill Clamps 9 Install Modules cont Module Slide Gliders to set Clamp Assemblies against the Module Base Glider Module Module 1 2 Gap Tongue Use Coupling alignment marks to center Coupling over the 1 2 gap Coupling can be offset of center the same procedures apply as identified in Step 9b Left Right Positioning...

Page 25: ...ustability is reduced due to the non metallic area of influence This area of influence varies by Module make and therefore a close visual inspection must be done to ensure that the Bonding Clip has cleared these areas Non Metallic Corners Alignment Mark places Bonding Clip on the non metallic portion of frame Alignment Mark places Bonding Clip on the metallic portion of frame Incomplete Bond Compl...

Page 26: ...dules will need to be evaluated by eye and leveled row by row 1 From the roof visually evaluate the rows for a consistent level left to right uphill downhill and to the row below Ideally get an evaluation from someone on the ground as well 2 If elevation adjustments are required raise or lower the Glider positions as needed on their respective Bases to bring things into level 3 After leveling tigh...

Page 27: ...irts create continuously bonded row left and right Now that the system is installed its time to add additional Bonding Clips referred to as uphill Bonding Clips to bond the system row to row Row to row bonding must be completed in one location at the end of every row This must be done between the skirt and the first row of modules and between every row of modules The image at left shows the genera...

Page 28: ...Clamp Slide Row to Row Bonding clip onto uphill side of the Upper Clamp Slide Row to Row Bonding clip onto uphill side of the Upper Clamp Module to Module Skirt to Module Factory installed Bonding Clip Factory installed Bonding Clip Module Torque Clamp to 14 ft lbs Skirt Row to Row Bonding Clip Row to Row Bonding Clip Torque to 14 ft lbs 23 of 31 EcoX Gen2 Installation Guide Rev 1 11 ...

Page 29: ...e Bonding Jumper bonds Skirt to Module Specialized bonding clips clip onto the underside flange of Module frame U n d e r s i d e F l a n g e U n d e r s i d e F l a n g e 11 Grounding and Bonding cont Note Bonding Jumpers are single use only Note Bonding Jumpers are single use only 24 of 31 EcoX Gen2 Installation Guide Rev 1 11 ...

Page 30: ... gage of the EGC wire to be used The installer is also responsible for obtaining prior approval from the AHJ for the use of any grounding lug not listed above Ensure that bare copper wire is isolated from all aluminum components Module any location approved by the module manufacturer Ground Lug 11 Grounding and Bonding cont One ground lug per array must be installed Ground lug can be installed on ...

Page 31: ...EcoX Gen2 Installation Guide Rev 1 11 26 of 31 11 Grounding and Bonding cont ...

Page 32: ...EcoX Gen2 Installation Guide Rev 1 11 27 of 31 11 Grounding and Bonding cont ...

Page 33: ...EcoX Gen2 Installation Guide Rev 1 11 28 of 31 11 Grounding and Bonding cont ...

Page 34: ...bond Continuous bond from Flashing through Clamp to Module Couplings bond Module to Module Complete row of Modules and EcoX components clamped to Modules are bonded Row to row bonding Bond Clip added to uphill side of one Clamp per row This bonds Skirt row to Modules on downhill row and Module row to next Module row on each subsequent row 1 2 3 1 2 2 3 3 3 Coupling Coupling Skirt Base Flashing Cla...

Page 35: ...atures an integrated Bonding Clip This Clip bites onto the Skirt on the downhill row Coupling Bonds Skirt to Skirt The Coupling features two integrated Bond Clips These clips bond each Skirt to the neighboring Skirt Base Base Strut Nut Strut Nut Clamp Assembly Clamp Assembly Clamp Coupling Coupling Bonding Clip Bonding Clips Bonding Clips Skirt Skirt Skirt 1 Skirt 2 Skirt 30 of 31 11 Grounding and...

Page 36: ...t row to the first row of Modules and to bond each row of Modules together There are two options to accomplish this they are as follows Option 1 Add a Bond Clip to the uphill side of each Clamp Option 2 Use an approved bonding jumper A jumper is required between the Skirt and the first row of Modules and between every row of Modules Either side of the array is acceptable Coupling Integrated Bondin...

Page 37: ...per and Lower Clamps from the Glider by removing the Strut Bolt and Strut Nut Position the Coupling onto the Glider and re install the Strut Bolt and Strut Nut Return the Glider to its original position on the Base Align the Glider and Coupling to the Modules as described in sections 8 9 and A 2 Tighten and torque the Strut Bolt and Coupling Clamp to 14 ft lbs Rafter happens to fall where two Modu...

Page 38: ...s Upper Clamp will fail to make proper contact with the Modules and or Skirts Correct positioning to the Alignment Marks ensures the Bonding Clips are making contact with the Modules and or Skirts concluding in a proper bond Module Module Skirt Skirt Incorrect Coupling position exceeds the allowable range Alignment Mark is not in line with Module Frame Inadequate Module and Skirt support Bonding w...

Page 39: ...e each sub array s left right length L do not exceed 35 ft Add Clamps as necessary to support PV modules on each side of the thermal break without exceeding the allowable cantilever specified in the project specific engineering calculations The leftt right gap between sub arrays should be set to a minimum of Note that the gap shown at left is much greater than for demonstration purposes Use a bond...

Page 40: ...ndy CL50 1TN Other UL 2703 listed outdoor rated by others ground lugs may also be suitable for this system if approved by the AHJ Authority Having Jurisdiction Install ground lug on both of the modules adjacent to the module to be removed Use the grounding hole on the frame of the module See section 10 for additional ground lug information B Connect a Bonding Jumper Lay a bare 6 CU conductor by ot...

Page 41: ...Q PRO BFR G4 CTXXXMxx 01 CTXXXMxx 02 40 psf 40 psf 23 3 psf Canadian Solar BM60 XXX BB FLV MA XXXP60AB CS6P XXXM CS6P XXXP JKMXXXM 48 JKMXXXM 60 JKMXXXM 60B JKMXXXM 60 V JKMXXXPP 60 JKMXXXPP 60 Plus JKMXXXPP 60 J4 JKMXXXPP 60 V JKMSXXXPP 60 40 psf 40 psf 40 psf 30 psf 30 psf 40 psf 23 3 psf 23 3 psf 23 3 psf LG Electronics LGXXXE1C A5 LGXXXN1K A5 LGXXXN1C A5 LGXXXN2W A5 LGXXXQ1C A5 LGXXXS1C A5 LGX...

Page 42: ... II TSM XXXPD14 TSM XXXPE14A 40 psf 40 psf 23 3 psf 40 psf 40 psf 23 3 psf Solaria PowerXT XXXR BX PowerXT XXXR PX EcoX is rated to be installed with the following Modules according to the approval list D 2 Appendix D Modules Evaluated as part of EcoX UL 2703 Certification cont Note XXX represents module wattage Manufacturer Module Series Max Downforce Max Uplift Max Downslope 30 5 psf 30 psf 23 3...

Page 43: ...V module as well as on long edge as shown The bracket must be fully inserted onto the return flange of the PV module See Figure 2 The power accessory unit must face downward as shown in Figure 2 The connection bolt must be tightened to a torque value of 14 ft lbs as shown in Figure 2 Additionally when the Power Accessory Bracket is used to install an Enphase unit with integrated grounding the conn...

Page 44: ...start here Lowest Position Dovetailed Engagements change elevation in 1 4 increments Glider Align Highest setting Mark of Glider to top of Base Align Middle setting Mark of Glider to top of Base Align Lowest setting Mark of Glider to top of Base 1 range of adjustment 1 4 increments between High Low positions Clamp Assembly includes Glider Base 1b Install the Clamp Assemblies Glider Acceptable rang...

Page 45: ... of the Glider includes one String Groove specifically designed to assist with this process Run and secure the String Line between the two outermost left right Clamp Assemblies Place String on the top String Grooves pulling it taught and securing its ends Torque to 14 ft lbs 2a Run a E W String Line String Groove Run String on uphill side of Clamp Assembly Position String on top groove of the two ...

Page 46: ...em Top Groove not aligned with String Line Base String Groove Top Groove Height Adjustments F 3 Uphill Downhill Adjustments String Line Gap Problem Gap too large between String Line and Glider Solution sliding Glider Toward String leaving a gap of 1 16 or less Reduce gap by String Line Glider Glider Base Base Appendix F Level and Align Clamp Assemblies cont EcoX Gen2 Installation Guide Rev 1 11 ...

Page 47: ...rame has fully seated into against the Clamps Place Module on Gliders Rest Module on uphill Base Pivot Module downward while pushing it into the Clamp Assembly 1 1 2 2 3 3 Uphill Base Clamp Assembly m odule starting position module resting position View looking from left edge 4 Ensure that Module is fully seated in Clamp Assembly and Coupling 4 module F 4 Appendix F Install Modules EcoX Gen2 Insta...

Page 48: ... the gap by the alignment marks on the Coupling s and aligning the Module frames to these marks As each row of Modules is installed complete all wiring connections and verify that all wire management clips and wires are properly arranged and off the rooftop before proceeding to the next row of Modules Wiring Install home runs or trunk cable if necessary as each row of modules is installed F 5 Appe...

Page 49: ...ng its alignment marks to set the gap of the Modules Tighten the two bolts and torque to 14 ft lbs After installing the Couplings return to step 9c and continue the installation process Torque to 14 ft lbs F 6 Appendix F Install Modules cont Torque 14 ft lbs 2 places 3c Installing the Coupling EcoX Gen2 Installation Guide Rev 1 11 ...

Page 50: ...sult the manufacturer of the attachment flashing in use to obtain proper installation instructions 1 Determine attachment locations Plan out the array on the roof and mark the location of each clamp using a chalk line or other appropriate method 3 Install the Flat Roof Base to the mounting stud Place the mounting hole of the Flat Roof Base ES10274 over the mounting stud and secure with the include...

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