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SLK SOLAR PV MODULE, Assembly Instructions Manual

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SLK SOLAR PV MODULE Assembly Instructions Manual Download Page 9

 

 

 
 
               

Assembly

 

instructions

 

for

 

SLK

 

Solar

 

roof

 

mount

 

system

‐ 

Rev

 

L

         

  

 

Page

 

9

 

of

 

38

 

 

ASSEMBLY

 

AND

 

INSTALLATION

 

SEQUENCE

 

 

1.

 

Assemble

 

tilt

 

bracket

 

bending

 

jig.

 

2.

 

Assemble

 

tilt

 

brackets.

 

3.

 

Install

 

tilt

 

brackets

 

and

 

longitudinal

 

links

 

on

 

roof.

 

4.

 

Lay

 

out

 

modules

 

and

 

spars

 

on

 

saw

 

horses.

 

5.

 

Attach

 

clamp

 

blocks

 

to

 

spars.

 

6.

 

Attach

 

modules

 

to

 

spars.

 

7.

 

Install

 

grounding

 

screws

 

8.

 

Attach

 

pivot

 

blocks

 

and

 

anchor

 

blocks

 

to

 

spars.

 

9.

 

Attach

 

panels

 

to

 

tilt

 

brackets.

 

10.

 

Hook

 

up

 

module

 

leads.

 

11.

 

Attach

 

lateral

 

links.

 

12.

 

Attach

 

wind

 

deflectors

 

on

 

north

 

rows.

 

13.

 

Install

 

end

 

discs.

 

14.

 

Install

 

ballast

 

pans

 

and/or

 

connector

 

post

 

assemblies.

 

 
 
 

Summary of Contents for PV MODULE

Page 1: ...d tools Page 5 Part diagrams Page 5 Elevation Views Page 7 Assembly sequence Page 9 Tilt bracket assembly and installation Page 10 Substrate assembly Page 12 Panel assembly 4x1 3x1 Page 13 General module to spar grounding Page 17 Tilt Access Feature Page 18 Panel installation Page 19 Lateral link assembly Page 21 Wind deflector assembly Page 22 Ballast pan installation Page 28 Connector installati...

Page 2: ...ontrol crafts with respect to work precedence and coordination Build rate Estimated mechanical installation rate modules per day for an array consisting of commercial class modules installed with a SLK Solar RMS and assuming a well equipped four person crew is on the roof and working 7 5 hours day with full task interchangeability 120 modules day As built documentation process On roof use and mark...

Page 3: ...s to ensure roofing system array compatibility WARNING Single ply roofs are not damage tolerant Avoid accumulation of metal fines that result from drilling or sawing metal components Metal fines embedded in the soles of shoes can damage single ply roofs Fasteners All required fasteners are furnished with the SLK Solar RMS All fasteners are 18Cr 8Ni stainless steel For any assembly finish initial b...

Page 4: ... in a semi formed condition and need final forming to be completed on site and are then attached to the tilt bracket bases This minimizes on site storage and reduces shipping and handling bulk Assembly time for tilt bracket is about 10 seconds The assembly process is worker friendly As is true for any precision assembly a light touch works best Do not over bend the tilt bracket cover C TILT ACCESS...

Page 5: ...with torque adjustment 4 Rubber mallet 5 1 2 wrench 6 9 16 wrench 7 1 1 8 wrench 8 Hex bit drivers 3 16 5 32 7 32 9 Drift pin 10 Wire cutters 11 Pliers PART DIAGRAMS Spar aluminum extrusion Longitudinal link aluminum extrusion Anchor block aluminum extrusion Lateral link aluminum extrusion Pivot block aluminum extrusion Clamp block aluminum extrusion Tilt bracket base aluminum sheetmetal Tilt brac...

Page 6: ...West wind deflector aluminum sheetmetal End East deflector aluminum sheetmetal End West deflector aluminum sheetmetal End disc aluminum extrusion Deflector clip Stainless steel Drill jig Long link clamp stainless steel Z Clamp Arm stainless steel Ballast pan aluminum sheetmetal Flashable post anchor FPA machined welded aluminum ...

Page 7: ...ackets are transparent for clarity PV Module Tilt bracket Pivot block Anchor block End Disc Wind deflector Spar Clamp block Lateral link End row tilt bracket smaller size than tilt bracket Wind deflector North end row tilt bracket Anchor block Tilt bracket Clamp block PV Module Pivot block End Disc Long Link Spar Tilt bracket End row tilt bracket smaller size than tilt bracket Long Link ...

Page 8: ...d deflector Lateral link Clamp block Pivot block Anchor block End disc Spar Tilt bracket PV Module End row tilt bracket smaller size than tilt bracket Lateral link Clamp block PV Module Pivot block End disc Spar Anchor block Tilt bracket End row tilt bracket smaller size than tilt bracket Wind deflector End row tilt bracket smaller size than tilt bracket End row tilt bracket smaller size than tilt...

Page 9: ...ongitudinal links on roof 4 Lay out modules and spars on saw horses 5 Attach clamp blocks to spars 6 Attach modules to spars 7 Install grounding screws 8 Attach pivot blocks and anchor blocks to spars 9 Attach panels to tilt brackets 10 Hook up module leads 11 Attach lateral links 12 Attach wind deflectors on north rows 13 Install end discs 14 Install ballast pans and or connector post assemblies ...

Page 10: ...cover to the tilt bracket base as shown in step 3 below Attach a longitudinal link between the two tilt brackets as shown below using two 2 3 8 16 x 2 25 HHCS and 3 8 Hex nuts note longitudinal link is only attached to the upper hole in the tilt brackets when used as jig The bending jig is now ready to be used Step 2 Bend tilt bracket covers Lay a tilt bracket cover over the longitudinal link and ...

Page 11: ... the tilt bracket cover until the slots in the cover clear the locking tabs in the base Allow the cover to expand with the locking tabs of the base engaging with the slots in the cover Push down on the center of the cover to complete engagement of tabs Ensure all locking tabs are engaged properly Pinch cover and align locking tabs with slots Release and engage locking tabs push cover down to compl...

Page 12: ...between tilt brackets as shown below Use four 4 3 8 16 x 2 25 HHCS eight 8 3 8 flat washers and four 4 3 8 hex nuts to attach the longitudinal link to the tilt brackets Use a washer on each side of the tilt bracket Do not fully tighten the nuts Repeat for second column of tilt brackets Parts Used Tilt bracket cover Tilt bracket base Long link 3 8 16 x 2 25 HHCS 3 8 16 Hex nut 3 8 Flat washer ...

Page 13: ... surface for holding tools and components Step 2 Module and Spar Preparation Spars are used as the main component of the panel assemblies Modules are affixed directly Lay modules face down with an approximate module to module gap of 1 25 Lay two 2 spars on top of the edges of the modules Orient modules such that junction boxes are in same direction for all modules Spar PV Module Parts Used Spars C...

Page 14: ...lamp blocks The clamp blocks are used to provide equal spacing between modules Install three 3 clamp blocks per 4x1 spar and two 2 clamp blocks per 3x1 spar and 1 clamp block per 2x1 spar using one 1 5 16 18 x 1 25 BHCS per clamp block Leave clamp blocks loose Clamp block Module Spar ...

Page 15: ...rify that the clamp block flanges are positioned flush over each module and square with the spar Tighten all bolts to 11 14 ft lbs using cordless screwdriver Ensure cordless screwdriver is set to the correct torque During this process make sure the spars are seated with no gaps against the outside of the PV module frames Step 5 Install pivot blocks to spars Install two 2 pivot blocks onto the firs...

Page 16: ...block so that grooved surface is facing modules Attach anchor blocks to spar using two 2 3 8 16 x 2 25 bolts and 3 8 hex nuts Tighten to 16 20 ft lbs Note Depending on movement of panels on site the anchor blocks can be attached to the tilt brackets first The anchor blocks would then be attached to the spar after the panel is installed on the tilt brackets Anchor block ...

Page 17: ...Assembly instructions for SLK Solar roof mount system Rev L Page 17 of 38 General Module to Spar Grounding Recommendations Please refer to General Module to Spar Grounding Recommendations Rev A ...

Page 18: ... 3 8 16x2 25 HHCS s from the Anchor Block Tilt Bracket assemblies and one from each of the Pivot Block Tilt Bracket assemblies reference below image for exact hole locations 2 Lift the sub assembly 4x1 and 3x1 up to 100 degrees To hold the modules in position align the provided locking holes on the Tilt Bracket with the locking holes on each Pivot Block 3 Place one 3 8 16x2 25 HHCS into the lockin...

Page 19: ...the panel down and guide the anchor blocks into the north side tilt brackets Install two 2 3 8 16 x 2 25 HHCS with a 3 8 flat washer into each anchor block and attach a 3 8 flat washer and 3 8 hex nut on each bolt Do not tighten Install two 2 3 8 16x2 25 HHCS with 3 8 flat washers into each pivot block and fasten with 3 8 flat washers and nuts Once all bolts are installed and panels are in correct...

Page 20: ...g end disc to substrate Install end disc into open end of each tilt bracket located on the south side of each SLK Solar column Secure end disc with one 1 3 8 16 x 2 25 HHCS with two 2 3 8 flat washers and one 1 3 8 hex nut Tighten to 16 20 ft lbs End disc End row tilt bracket cover South row ...

Page 21: ...teral links are located between panels where shown on layout drawing Step 1 Attaching the lateral link to the spar Insert the lateral link within the spar channel of each panel and align mounting holes Install two 4 3 8 16 x 2 25 HHCS through spar and lateral link 2 each end and attach four 4 3 8 hex nuts Tighten to 16 20 ft lbs Lateral link assembly Lateral link Spar Parts Used Assembled panel La...

Page 22: ...ers Step 1 Installing deflectors to North row spar Install deflector mounting hardware to spars on North row Install 5 16 18 x 1 HHCS with 5 16 flange nuts into each Ø 344 hole on the back leg of the spar quantity varies depending on module type and whether a 4x1 3x1 or 2x1 is being used Torque to 14 16 ft lbs Note this step can be done when the panels are being assembled during the panel assembly...

Page 23: ...h E W deflectors to spars Attach east and west deflectors to spar using 5 16 18 flange nuts Orient the deflectors such that the end tabs are facing out and are at the center of the 4x1 3x1 and 2x1 panel Torque to 14 16 ft lbs End tabs of deflectors East wind deflector West wind deflector ...

Page 24: ... 38 Step 3 Attach deflector clips to end row tilt brackets Attach deflector clips to end row tilt brackets using two 2 5 16 18 x 625 BHCS per deflector clip Torque to 11 to 14 ft lbs Side view of deflector to tilt bracket assembly Deflector clip goes over lip on deflector ...

Page 25: ...ge 25 of 38 Step 4 Connect E W deflector tabs Connect east and west deflector end tabs at center of panel using 5 16 18 x 625 BHCS with flange nuts quantity varies between 0 and 4 depending on system Torque to 11 14 ft lbs Side view of north row assembly 10 system ...

Page 26: ...the side of the spar where the end wind deflector will be mounted Remove the upper anchor block to tilt bracket 3 8 16 x 2 25 HHCS with washers and hex nut Set fasteners aside Step 2 Attach end wind deflector Attach the end wind deflector to the back of the spar Install the two anchor block to spar mounting screws through the end wind deflector mounting holes Insert two 2 3 8 16 x 2 25 HHCS with 3...

Page 27: ...ab on the end wind deflector Torque to 16 20 ft lbs Note East end wind deflector shown procedure is the same for West end wind deflectors Array section showing east end wind deflector on a 4x1 and east and west deflectors on a 3x1 May need to field modify deflector Add west end deflector Drill two holes in spar If this module is omitted cut spars and deflector approximately 6 from tilt bracket cov...

Page 28: ...to each side of the ballast pan are used to secure the pavers to the pan Length of wire required will depend on ballast pan and number of pavers used for example a 24 ballast pan with 8 pavers would require approximately 6 of wire per pan 9 of wire is provided per pan for worst case Note A suitable waterproof adhesive can be used in place of the wire ties Use adhesive to attach the pavers to the b...

Page 29: ...f 38 Step 2 Placing ballast Lay required number of pavers onto ballast pan Place pavers as close as possible to long link Other paver layout options 16 ballast pan with 4 pavers 24 ballast pan with 4 pavers 12 16 Push pavers toward long link 4 pavers double stacked 16 24 ...

Page 30: ...de of ballast pan and twist it around itself two twists minimum to secure Step 4 Affixed tie down wire Pull wire taut and loop through hole on other side of ballast pan and secure by twisting wire around itself two twists minimum Hole in ballast pan Wire through hole and twisted around itself Wire pulled taut and secured each end ...

Page 31: ...iple tie down wires Repeat steps 3 and 4 for second wire Note Alternate single wire attachment method for 4 pavers high or fewer Loop wire through holes on one side of ballast pan Remove slack and loop ends through opposite side of ballast pan Twist wire around itself two twists minimum to secure ...

Page 32: ...minimum penetration Step 1 Install Flashable Post Anchor FPA Attach flashable post anchor FPA to roof and add flashing Section of roof with roofing material removed to allow direct access to substrate Backer board to bring connector base flush with deck Determined and supplied by others FPA Mounting screws Roof attachment hardware determined and supplied by others FPA with flashing installed Deter...

Page 33: ...arm to long link using long link clamp and four 4 5 16 x 625 BHCS with 5 16 flange nuts Do not tighten nuts Step 3 Install ZCA to FPA Connect Z clamp arm to FPA and secure with 3 4 10 x 1 5 HHCS and flat washer Tighten to 30 40ft lbs Tighten 5 16 nuts on long link clamp to 11 14 ft lbs Z clamp arm Long link clamp Flashable post anchor ...

Page 34: ...a 3x1 or vice a versa the tilt bracket of the of 3x1 that does not line up with the 4x1 column needs to be attached to the spar of the 4x1 To do this two 13 32 holes have to be drilled in the 4x1 spar to allow attachment of either a pivot block or anchor block which block to use depends on whether the 3x1 is to the north or south of the 4x1 This pivot block or anchor block will then be attached to...

Page 35: ...de of the 4x1 spar needs the extra mounting holes before beginning Step 1 Lining up spars Lay a 3x1 and 4x1 spar back to back and align one set of anchor pivot block holes on the 3x1 with the matching holes on the 4x1 Step 2 Affix spars together Clamp and bolt spars together to maintain alignment 4x1 spar 3x1 spar Align holes Side view ...

Page 36: ...p 3 Affix drill jig Connect the drill jig to the 3x1 spar at the second pivot anchor block location Tighten thumbscrew to secure the drill jig to the spar Step 4 Drill spar Using the drill jig as a guide drill two 13 32 holes through 4x1 spar Debur edges on both sides Drill jig ...

Page 37: ... connecting on north side using an anchor block Use anchor block as a guide to ensure that the drill jig is in the correct location Push drill jig into spar until it stops Secure drill jig to spar using jig thumb screw Drill two 13 32 holes in 4x1 spar Debur edges on both sides Tilt bracket of 3x1 4x1 North side spar Anchor block used as guide Drill jig Drill jig thumbscrew ...

Page 38: ...e anchor block as a guide to ensure that the drill jig is in the correct location Push drill jig into spar until it stops Secure drill jig to spar using jig thumb screw Remove anchor block Drill two 13 32 holes in 4x1 spar Debur edges on both sides Note Anchor block is only used as a guide a pivot block will be used to connect the 3x1 tilt bracket to the 4x1 spar 4x1 south side spar Drill jig Anch...

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