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TerraGen TGR, Installation Manual

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Tel: 705-435-7373   |   www.terragensolar.ca   |   [email protected]   |   120 Parsons Rd, Alliston, ON L9R 1E9 

 

 

 

 

 

 

 

 

Installation Manual 

TerraGen Environmental Group 

120 Parson Rd. 

Alliston, Ontario, L9R 1E9 

705-435-7373 

Version: 30/04/2021 

 

 

Summary of Contents for TGR

Page 1: ...5 435 7373 www terragensolar ca info terragensolar ca 120 Parsons Rd Alliston ON L9R 1E9 Installation Manual TerraGen Environmental Group 120 Parson Rd Alliston Ontario L9R 1E9 705 435 7373 Version 30 04 2021 ...

Page 2: ...6 6 2 Base Rail Installation 6 6 2 1 Base Rail Layout 6 6 2 2 Rubber Pad Installation 7 6 2 3 Base Rail Splicing 9 6 3 Top Rail Installation 9 6 3 1 Cross Adapter Setup 9 6 3 2 Top Rail Layout 11 6 3 3 Top Rail Splicing 12 6 3 4 Top Rail Thermal Breaks 12 6 4 Ballast Installation 13 6 5 Home Run Wiring 13 6 6 Module Installation 14 Appendix A Ballast Requirements 15 Appendix B Bonding Grounding 16...

Page 3: ...s are followed To ensure proper installation and prevent a void of your warranty the installation manual and the project specific documentation must be followed In unique or custom cases where alternative components or design is required the project specific documentation will supersede the installation manual where there is insufficient or conflicting information 2 Material Receiving A detailed b...

Page 4: ...above i e 3 8 or 1 2 drive OR Cordless drill and socket adapter for each of the above or Chalk line and measuring tape 7 ft lb and 12 ft lb pre set slip type torque wrenches OR an adjustable torque wrench or Miscellaneous Onsite cutting ability Cold galvanizing spray Use of impact tools when installing clamps and hardware will cause galling seizing of SS hardware TerraGen will not free issue compo...

Page 5: ...TGR System 4 Tel 705 435 7373 www terragensolar ca info terragensolar ca 120 Parsons Rd Alliston ON L9R 1E9 4 System Components ...

Page 6: ...s for any signs of defect Any components showing signs of damage that compromise safety shall be replaced immediately o Check for any deformation penetrating corrosion or other noticeable defects in the components o Inspect roofing condition around the contact points with the roof and that the system has not moved over time Ensure appropriate roof protection is still secured appropriately in place...

Page 7: ...blies are placed B is space between tilt assemblies S N B in most cases N and S represent the amount of base rail left over at the North end and South end respectively Base Rail Side View 6 1 2 Cutting Rails Please refer to the Construction Package for the cuts required for the project it is advantageous to set up a cutting station to prep all of these before installation 6 2 Base Rail Installatio...

Page 8: ...h a string or laser line can be helpful 6 2 2 Rubber Pad Installation A rubber pad is used to protect the roof membrane Place the rubber pad underneath the base rails before the placement of rails Typical rubber pad supply is a recycled rubber under the base rails that is not attached to the system TPV Rubber pad can be requested as a substitute for which see below for installation instructions Ba...

Page 9: ...ies the rubber pads as the first step of the installation Typical coverage is 30 pcs of the TPV Pad spaced 12 apart 1 Flip Base Rail over 2 Slide Rubber on to Base Rail Roof warranty holder should be contacted to ensure compatibility with the roof membrane and ensure the roof warranty is maintained if applicable Typical coverage is 30 pcs of the rubber pad spaced 30 apart If any part of the base r...

Page 10: ...stallation 6 3 1 Cross Adapter Setup Use cross adapters to secure the top rails to the tilt assemblies Click the cross adapter onto the tilt assembly to attach a top rail Unless otherwise specified on the Clean all metal shavings created from the provided metal screws and spray the assembly with a Cold Galvanizing Compound If roof slopes cause a drastic peak or valley that cannot be accommodated u...

Page 11: ...side configurations in the field Use the pattern shown below right to attach cross adapters on both sides of each rail for farthest east and farthest west columns All other interior columns receive cross adapters on the insides of top rails or outsides of top rails in alternating sequence Cross Adapters Find this distance d in the Construction Package B Cross Adapters on insides of top rails A Cro...

Page 12: ...ayout plan The layout plan can be found in the Construction Package Please refer to it for top rail cut lengths and positions The maximum overhang amount is also specified in the construction package and it is measured from the edge of the mounted panel to the base rail A minimum of 2 of top rail is required past the end of the module on the starting side Panel Overhang Refer to Const Pkg Top Rail...

Page 13: ... ends of the top rails 6 3 4 Top Rail Thermal Breaks In the case of extended rows where a thermal break is required refer to Construction Package a module break is required divided by two end clamps and a splice Top Rail Splice Top Rail Top rail Integrated Bonding Clip Top rail splice End clamp Solar module Gap Due to undulations on the roof surface the angle between the thermal break and the rail...

Page 14: ...d in the Construction Package TGR Assembly with Ballast Ballast Tray Alternative If ballast trays are required utilize the configurations below corresponding to the ballast plan of the Construction package 6 5 Home Run Wiring After top rail installation is complete this would be the best time to run all PV cable and home runs as this allows the installer to have free range of access to the racking...

Page 15: ...e next module is placed properly the mid clamp can then be secured and torqued to 12 ft lbs WEEB CCR2 Upon Request End clamp Mid clamp w Bonding washer End Clamp Mid Clamp Bonding Washer Min 2 See Note Top Rail In the circumstance where the modules being installed have 50mm frames care needs to be taken when installing mid clamps and end clamps as the bolt will be on its last few threads Hand loos...

Page 16: ...izes can be accommodated upon review and approval by TerraGen Refer to the project specific construction package for ballast weight quantity and placement Notes 1 RANGE OF DIMENSIONS D x H x W 15 3 8 x 7 1 2 x 3 1 2 to 15 9 16 x 7 1 2 x 3 5 8 2 ALLOWABLE WEIGHT VARIANCE 0 32 kg 0 71 lbs 3 Dimensions may slightly vary depending on location of blocks Mechanical Attachments An alternative method of u...

Page 17: ... pierces the surface of the aluminum rails Connection 3 Top Rail to Tilt Assembly Top rails are connected to tilt assemblies using cross adapters Connection 4 Tilt Assembly to Base Rail Tilt assemblies connect onto the base rails using the M8 50 mm bolt through the pre drilled holes and secured with the M8 serrated nut Connection 5 Base Rail to Base Rail 12 TEK screws 4 per side fasten the base ra...

Page 18: ...the roof of your building take time to pre assemble the tilt assemblies onto the bottom rail while still on the ground Using sawhorses to hold the work piece at waist height cut all necessary lengths Refer to your Construction Package for lengths of base rails Once cut place tilt assemblies onto the entire length lining them up to the holes Use the M8 bolt and serrated nut to fasten the tilt assem...

Page 19: ...ire management clips that TerraGen offers PHOTO 3 PV wire management using the optional wire management clips on the solar panel PHOTO 4 TGR base rails the north south rails can be used to secure wires requiring management from row to row We permit installers to secure wire management components to our base rail In this case the installer used PVC conduit PHOTO 5 Row to row DC wiring can be pulled...

Page 20: ...lar ca 120 Parsons Rd Alliston ON L9R 1E9 Appendix E MLPE Mounting T Bolt assembly is available upon request from TerraGen to mount MLPE microinverter or optimizer into the channel of TerraGen rails Ensure that guidelines from the MLPE installation manual are followed ...

Page 21: ...tified for Fire Rating and has a UL 2703 Fire Class A rating for low slope roofs with Type l and Type ll modules with the addition of the top rail on the Northern perimeter of each array The system will perform as expected provided it is installed over a fire resistant roof covering rated for the application Fire Shield Installation M8 x 50 Hex Bolt M8 Serrated Nut 19 66 Top Rail ...

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