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A Cemco Company
Installation Manual
Document PVC-1000 Rev. 7
Rev Level
6
7
Releaser
Robert Grant
Robert Grant
Installation Manual Rev. 7 2-12-20-15
Initials
RG
RG
Date
12-16-2014
2-12-2015
Table of Contents
1.
About this Manual.................................................................................................... 4
1.1.Introduction.............................................................................................................. 4
1.2.Scope....................................................................................................................... 4
1.3.
Load Considerations................................................................................................ 4
1.4.
Marine and Corrosive Environments....................................................................... 4
2.
Safety Notice........................................................................................................... 4
2.1.
Safety Notice........................................................................................................... 4
2.2.
Personal Safety....................................................................................................... 4
2.3.
Electrical Safety....................................................................................................... 5
2.4.
Cuts or Burns........................................................................................................... 5
2.5.
Heart Pacemakers................................................................................................... 5
2.6.Inhalation................................................................................................................. 6
2.7.
Eye or Head Injury................................................................................................... 6
2.8.Noise........................................................................................................................ 6
2.9.Chemicals................................................................................................................ 6
2.10. Proper Lifting Techniques........................................................................................ 6
2.11. Hand Safety............................................................................................................. 7
3.
Installer Responsibility............................................................................................. 7
4.
Installation Procedural Flow..................................................................................... 8
4.1.
PVcobra Installation Checklist Document Explanation............................................ 8
5.
Hardware Torque Value Chart.................................................................................. 9
6.
Recommended Tool List.......................................................................................... 10
7.
UL 2703 Bonding..................................................................................................... 11
7.1.
End of Row Grounding............................................................................................ 12
7.2.
Expansion Joint Bonding......................................................................................... 12
7.3.
Module to Hat Channel Bonding.............................................................................. 13
8.
Recommended Installation Procedure..................................................................... 14
8.1.
Fixed Tilt Column Installation................................................................................... 14
8.2.
RSB-C Beam Installation......................................................................................... 15
8.3.
Angle Brace Installation........................................................................................... 16
8.4.
Hat Channel Installation........................................................................................... 18
8.5.
Module Installation................................................................................................... 20
9.
Operation and Maintenance.................................................................................... 21
10.
Elco EDC801 Spec Sheet........................................................................................ 22
11.
UL SU 2703 Bonding Test Letter............................................................................. 23
12.
PVcobra Installation Checklist................................................................................. 24
1.
About this Manual
1.1. Introduction
The purpose of this manual is to describe the installation procedures for the PVcobra Fixed Tilt
Mounting System. It is required that the Installer adheres to these instructions in order to ensure
the system will function as intended by the manufacturer. If the installer decides not to follow
these instructions PVcobra cannot be held responsible for the overall performance or safety of
the system. This manual is to be used in conjunction with a stamped construction drawing set.
1.2. Scope
This manual describes how to properly construct the PVcobra ground-mount, fixed-tilt racking
system to ensure that the qualified bonding path is maintained. Site-specific engineering
evaluations must be performed to assess the impact of environmental conditions, including wind
and snow load. This manual does not include electrical assembly with respect to actual power
generation.
1.3. Load Considerations
This product is configurable to permit any length of PV arrays with the longest single length of
construction at 60 ft. For this maximum single rail size, the system is designed to hold up to
thirty-six (36) 72-cell modules. This system is to be used only in combination with modules that
include this specific rack system in their installation manual. A qualified structural professional
engineer is expected to determine the actual number and size of modules intended for each site.
1.4. Marine and Corrosive Environments
PVcobra systems are not suitable for marine climates or corrosive environments.
2.
Safety Notice
2.1. Safety Notice
This manual contains important safety instructions, which you must thoroughly understand and
conform with. Failure to adhere to the guidelines set forth in this manual could result in personal
injury or equipment damage. Failure to follow the instructions in this chapter may void equipment
warranties.
To prevent unnecessary risk of fire, electrical shock or personal injury, all wiring and grounding
must be done in accordance with local codes. Or, in the absence of local codes, with the National
Electrical Code, ANSI/NFPA No. 70 - Latest Revision (For the US) or the Canadian Electrical
Code CSA C22.1 – Latest Revisions and local codes and ordinances. The appropriate governing
electrical code will henceforth be referred to as “Electric Code” in this document.
2.2. Personal Safety
A.
Any loose clothing, jewelry, or unsecured long hair can potentially become tangled in
moving parts, resulting in possible serious injury. Wear appropriate clothing and adequately
maintain long hair. Keep all items clear of moving components.
PVcobra Installation Manual Rev. 7
Page 4
B.
Never perform work when you are fatigued or under the influence of alcohol, drugs, or
other medication.
C.
Keep your work areas clean, well lit, and well-ventilated at all times.
D.
Keep all unauthorized personnel away from your work area at all times.
E.
Always stay alert. Inattention can result in death, serious personal injury, and/or property
damage.
F.
Always shut off and unplug electrical tools when not in use. Remove adjusting keys and
wrenches before operating.
G.
Always wear appropriate PPE (Personal Protective Equipment) while working.
H.
Maintain proper footing and balance at all times. Improper lifting techniques can cause
severe personal injury.
I.
Understand and comply with all safety instructions for all tools you are using during the
installation process.
2.3. Electrical Safety
A.
Always shut down electrical components prior to performing any work on them. Never
perform work on any electrical component while in contact with water or conductive materials.
B.
Read, understand and comply with all electrical safety instructions for all electrical tools
that you use.
C.
Use extreme caution when drilling, nailing, or cutting into any wall or other surface that
might contain hidden electrical wiring or components.
D.
Electrical components and tools can cause sparks that can ignite dust or fumes. Never
operate any electrical component or tool where there is a risk of fire from flammable liquids,
gases, or dust.
2.4. Cuts or Burns
A.
Keep your hands and body well away from the working parts of any tool you use during
the PVcobra installation. Failure to comply with tool safety guidelines could result in serious
injury.
B.
Wear work gloves and other appropriate protective apparel or equipment based on the
needs of the situation.
2.5. Heart Pacemakers
A.
Personnel with heart pacemakers must consult their physician before coming into close
proximity to any electrical components such as meters, transformers, breaker panels or inverters.
The electromagnetic fields generated by these devices can cause the pacemaker to fail, possibly
resulting in serious injury or death.
PVcobra Installation Manual Rev. 7
Page 5
2.6. Inhalation
A.
When possible, always work in a well-ventilated area. Ensure that the workspace is free
of dust, mold, vapors, or other harmful substances.
B.
Be aware that tools used during installation can create dust and other inhalation hazards.
Always wear a properly fitted MSHA/NIOSH approved face mask or respirator in potentially
hazardous environments.
C.
Make sure that all respiratory protection you wear is appropriate for the given situation.
2.7. Eye or Head Injury
D.
Some of the power tools you may use during the installation are capable of propelling
materials such as sparks, fasteners, metal chips, saw dust, and other debris at high speed,
which could result in serious eye injury. Always wear appropriate eye protection (ANSI Z87.1).
E.
Tool attachments can become loose or break and fly apart, propelling debris at high
speed. Always wear appropriate eye protection (ANSI Z87.1).
2.8. Noise
A.
Always wear approved ear protection when working in noisy environments. (ANSI S3.19)
B.
Tools and some electrical components produce noise during operation. Prolonged
exposure to noise levels above 85 dBA can cause hearing damage.
2.9. Chemicals
A.
Some electrical components contain hazardous materials and/or produce ozone, a
harmful gas. Avoid bodily contact with hazardous chemicals in any form (solid, liquid, or gas).
B.
Should you happen to come in contact with any hazardous substance, follow all appropriate
first aid instructions and seek emergency medical treatment.
2.10.Proper Lifting Techniques
A.
Before lifting, size up the load and test it to see if you can lift it safely. Ensure that you can
grasp it securely, and make sure the load is balanced in your hands.
B.
Get as close to the load as possible before lifting it.
Make sure your footing is secure. Never lift objects that will obscure vision or footing.
C.
Never twist while lifting. Move your feet so that they point in the same direction of the lift
as you turn.
D.
Lift smoothly, but not slowly. Do not jerk the load.
E.
Organize the work so as to avoid lifting from the floor or above shoulder level. Items to be
handled should be between knee and shoulder height.
PVcobra Installation Manual Rev. 7
Page 6
F.
If you have a lot of lifting to do during the day, try not to do it all at once. Alternate lifting
tasks with lighter work to give your body a chance to recover. Remember, mechanical assistance
is just as important for repetitive lifting as it is for heavy lifting.
G.
Use the same principles when lowering or placing the load after lifting. Place carefully.
H.
Try to avoid carrying the load more than 10 feet without getting mechanical assistance.
Use a dolly or cart.
2.11. Hand Safety
A.
Maintain good hand position to avoid hazards. You must be constantly alert to where your
hands are positioned. Pay special attention to the placement of your non-dominant hand.
B.
Maintain an effective barrier between hands and hazards by using tools or other aids.
C.
Make sure machine guards are in place for all moving machinery. Never remove machine
safeguards.
3.
D.
Check materials and equipment for rough or sharp edges before handling.
E.
When applying force (push or pull) be prepared for an unexpected slip or release.
Installer Responsibility
A.
Installer has the responsibility to comply with all applicable local and National Codes.
B.
Installer shall ensure that all of the components supplied by PVcobra are not substituted
without additional evaluation (by the NRTL).
C.
Installer shall ensure a safe installation of all electrical aspects of the Solar Array.
D.
The installer has the responsibility to ensure all of the system support posts are installed
within the tolerances established by the system manufacturer. Refer to section 7.1 for allowable
support post tolerances.
PVcobra Installation Manual Rev. 7
Page 7
4.
Installation Procedural Flow
1. Layout Array
6. Install PV
Modules & Finalize
Thermal Expansion
Joints
2. Pre-Stage &
Install Foundations
5. Distribute and
Install Hat Channel
3. Pre-Stage &
Install RSB’s
4. Align RSB’s
& Fasten Kicker
from RSB’s to
Foundations
4.1. PVcobra Installation Checklist Document Explanation
The diagram above provides an overview of the steps required to assemble the PVcobra system.
The rest of this document provides details for each step identified. The PVcobra Istallation
Checklist must be filled out, inspected and signed during the course of constructing this mounting
system. This checklist must be returned to the manufacturer as a record of proper installation to
reduce the risk of warranty and liability issues.
PVcobra Installation Manual Rev. 7
Page 8
5.
Hardware Torque Value Chart
Part Description
Torque Value
WEEB-LUG-6.7
WEEB-BNDJMP BONDING STRAP
MODULE MOUNTING HARDWARE
#12 Tek Screws
1/2” Hardware
7 ft. lbs.
10 ft. lbs.
14 ft. lbs. Minimum
10 ft. lbs
50 ft lbs.
X731
1/2” Flanged Hex Bolt
X732
1/2” Flanged Hex Nut
X 735
Simpson Shoulder Screw
X734
#12 Tek Screw
X737
M8 Flanged Bolt
X738
M8 Int./Ext. Star Washer
X736
M8 Flanged Nut
PVcobra Installation Manual Rev. 7
Page 9
6.
Recommended Tool List
Builder’s Level
Digital Protractor or Angle
Indicator
Vise Grips – Swivel Pad
(Irwin 12# SP)
¾” Socket & Ratchet
¾” Open End Wrench
Milwaukee 6790-20 Screw Gun
and 5/16” adapter
Sharpie
PVcobra Installation Manual Rev. 7
Page 10
7.
UL 2703 Bonding
The PVcobra solar mounting structure has been designed and manufactured to conform to
the bonding requirements of UL 2703. Each separate/individual row is a completely bonded
structure which permits the use of an approved ground lug at the end of each row.
To prevent unnecessary risk of fire, electrical shock or personal injury, all wiring and grounding
must be done in accordance with local codes. Or, in the absence of local codes, with the National
Electrical Code, ANSI/NFPA No. 70 - Latest Revision (For the US) or the Canadian Electrical
Code CSA C22.1 - Latest Revisions and local codes and ordinances.
PVcobra Installation Manual Rev. 7
Page 11
7.1. End of Row Grounding
A solid copper equipment grounding conductor (sized per the
Electric Code) is intended to be connected to a WEEB-LUG-6.7
attached to the hat section with the supplied hardware that comes
with the WEEB-LUG-6.7. The equipment grounding conductor
(EGC) shall be run with PV source circuit conductors to the
equipment grounding busbar in the PV source circuit combiner
box. The grounding busbar in the PV source circuit combiner is
required to be connected to the EGC for the PV output circuit that
is terminated in the PV output circuit combiner (if used) or in the
inverter where the power is converted from dc to ac.
WEEB-LUG-6.7
If required by the Electric Code, provide grounding electrode conductor(s) using one of the two
following methods:
At each electrically separate structure, a 5/8” diameter, 8-foot long copper clad grounding electrode
shall be installed in accordance with 250.53. An electrically separate structure shall be a structure
that is not bonded to another structure with a minimum of a 6AWG solid copper bonding jumper
or equivalent. Only one grounding electrode shall be required for each electrically separate
structure. The electrically separate structure shall be connected to the grounding electrode with
a 6AWG solid bare copper conductor from a lug (ANSI/UL467) on the structure to a connector
listed for the 5/8” grounding electrodes on the grounding electrode.
Alternatively, if the PV source circuit combiner is located in the vicinity of the structure, a 6AWG
solid bare copper conductor may be run from the PV source circuit combiner box busbar to a
connector listed for the 5/8” grounding electrodes on the grounding electrode. This alternative
connection method is allowed since the structure is also required to be connected to the PV
source circuit combiner box grounding busbar as described in the description provided for item.
7.2. Expansion Joint Bonding
A WEEB Bonding Jumper Part # WEEB-BNDJMP listed to UL467 is being utilized to bond
adjoining hat sections, at the location of the dynamic thermal expansion joints. This strap is
acting as a redundant bonding path.
One out of 4 continous hat channel runs must be bonded with a WEEB-BNDJMP at each thermal
expansion joint to maintain a continous bonding path along the entire array row.
WEEB-BNDJMP
Part #
Torque Value
WEEB-LUG-6.7
WEEB-BNDJMP BONDING STRAP
MODULE MOUNTING HARDWARE
7 ft. lbs.
10 ft. lbs.
14 ft. lbs. Minimum
PVcobra Installation Manual Rev. 7
Page 12
7.3. Module to Hat Channel Bonding
Please consult the Module Manufacturer’s released installation manual. The PVcobra system
uses the Module Manufacturer’s approved thru-bolt module mounting locations utilizing a
Stainless Steel 5/16” flanged bolt and nut. When installing the module a stainless steel internal/
external tooth lockwasher is placed between the module frame and hat channel. Only one (1)
washer is required per module. The torque value of the fasteners are ascertained from the
specific Module Manfacturer’s installation manual and specific to the module being mounted.
PVcobra requires a 14ft .lbs min torque value.
(Aluminum)
See Permit Documents
Part # (EIT-0312-24-00-410SS-PAS)
(1) Star Washer Required Per Module
PVcobra Installation Manual Rev. 7
Page 13
8.
Recommended Installation Procedure
8.1. Fixed Tilt Column Installation
Parts Needed
Part #
Description
Qty
X705
Fixed Tilt Column
1
A.
The Fixed Tilt Column Layout is determined by solar module size,
and is specific to each site. Refer to your site layout drawing. Please call
before you dig. Calling 811 before every digging job gets your underground
utility lines marked for free and helps prevent undesired consequences.
B.
Fixed Tilt Columns must be installed within a tolerance of 1/2” in the X and Y direction at
the top of the Fixed Tilt Column, in accordance with Fixed Tilt Column placement in the approved
site layout plans of each installation site. Fixed Tilt Column rotational orientation must be no
more than 2 degrees.
C.
Fixed Tilt Columns in a row must all be the same elevation within +/- 1/2”.
PVcobra Installation Manual Rev. 7
Page 14
8.2. RSB-C Beam Installation
Parts Needed
Part #
Description
Qty
X704
X732
X731
RSB-C Beam
1/2” Flanged Nut
1/2” Flanged Bolt
1
1
1
A.
Lift the RSB-C Beam into position. The hard side of the RSB-C Beam and the flat of the
Fixed Tilt Column should be facing each other.
B.
Line the slots up on the RSB-C Beam and the Fixed Tilt Column and push the 1/2” Flanged
Bolt though the slots RSB-C Beam Side first.
C.
Use the 1/2” Flanged Nut to secure the RSB-C Beam. Torque 1/2” Hardware to 50 ft. lbs.
D.
The 9/16” Hole in the RSB-C Beam should be facing the direction the PVcobra will tilt.
PVcobra Installation Manual Rev. 7
Page 15
8.3. Angle Brace Installation
Parts Needed
A.
Part #
Description
Qty
X703
X732
X731
X734
Angle Brace
1/2” Flanged Nut
1/2” Flanged Bolt
#12 Tek Screws
1
1
1
7
Line up the 9/16” holes on the Angle Brace and the RSB-C Beam.
B.
Using the 1/2” Flanged Bot and Nut attach it to the RSB-C Beam. Torque 1/2” Hardware
to 50 ft. lbs.
PVcobra Installation Manual Rev. 7
Page 16
C.
Using a digital level, set the RSB-C Beam to the proper angle specified in the approved
construction drawings.
D.
Swing the bottom of the Angle Brace to the Fixed Tilt Column and secure with 3 #12 Tek
Screws.* Torque Tek Screw hardware to 10 ft. lbs.
E.
When the Angle Brace is secured, drill 4 more #12 Tek Screws and lock the final position
of the RSB-C Beam. Torque Tek Screw hardware to 10 ft. lbs.
Installer Responsibility
*NOTE - A standard screwgun with a depth sensitive nosepiece should be used to install the
Tek Screws. For optimal fastener performance, a minimum 4.5 to 5.0 amp tool with a drive
speed of 1,800 to 2,000 rpm is recommended. Proper adjustment of the nose piece is required
for the correct seating of the fastener.
PVcobra Installation Manual Rev. 7
Page 17
8.4. Hat Channel Installation
Parts Needed
Part #
Description
Qty
X701
X702
X734
X008
Hat Channel
Hat Channel
#12 Tek Screws
Simpson Shoulder Screw
4
4
48
4
A.
Depending on where you are on construction of the row, X701 or X702 Hat Channel will
be used. They are designed to alternate every 3rd table in an “overlapping / nested” condition
eliminating a separate angle clip needed for the “splice” connection.
B.
Spacing between Hat Channels is determined by solar module size, and is specific to
each site. Refer to your site layout drawing.
C.
One Hat Channel Spans 3 of the RSB-C Beam Post assemblies. Starting with the end of a
row hang a X701 Hat Channel 6” past the end of the RSB-C Beam and at the height designated
by the site layout drawings.
PVcobra Installation Manual Rev. 7
Page 18
D.
Attach alternate hat channels using a #12 Simpson Shoulder Screw. Make sure to center
the screw in the bottom purlin flange slot. This will allow for a sliding thermal expansion slot.
Approved
Overlap
EQ EQ
#12 Simpson Shoulder Screw installed in the center of the purlin flange slot. The screw should
match at each location.
Not Approved
Overlap
PVcobra Installation Manual Rev. 7
Page 19
8.5. Module Installation
Parts Needed
Part #
X736
X737
X738
Description
5/16” x 1” Serrated Flanged Hex
Bolt
5/16” Serrated Flanged Hex Nut
5/16” Star Washer
Qty
1
1
1
A.
PVcobra’s installation procedure is to mount the modules directly to the Hat Channel.
Using the 5/16” x 1” Serrated Flanged Hex Bolt, 5/16” Serrated Flanged Hex Nut, and 5/16” Star
Washer. The torque value of the fasteners are ascertained from the specific Module Manfacturer’s
installation manual and specific to the module being mounted.
PVcobra Installation Manual Rev. 7
Page 20
9.
Operation and Maintenance
The PVcobra requires minimal maintenance. This section outlines the procedures for inspecting
and maintaining the system to ensure proper function. The PVcobra should be maintained every
two years. Every two years walk the jobsite and inspect for any fasteners that are missing or
loose. Perform a thorough visual inspection on all surfaces of material and fasteners for rust.
You are looking for any degradation of coating on the steel. Any areas of rust should be treated
in accordance with ASTM A-780. A log is required to record the results of every inspection.
O&M Log
Date
Inspectors Name
Company
Site Name
Are there any fasteners missing?
Corrective action taken
Is there any rust or degradation of steel
coating?
Corrective action taken
Notes
Signature of Inspector
* Copy of O&M logs must be sent to [email protected]
PVcobra Installation Manual Rev. 7
Page 21
10. Elco EDC801 Spec Sheet
11. UL SU 2703 Bonding Test Letter
12. PVcobra Installation Checklist
Project Name
Project #
1. Foundations
Number
Description
Posts are in tolerance in the X and Y
1.1
Position
1.2
2. RSBs
Number
2.1
Pass Fail Open Item
Observations
Pass Fail Open Item
Observations
Posts are set to the correct elevation
Description
RSBs are installed at the correct
elevation.
2.2
RSBs are installed at the correct angle.
2.3
RSBs are installed with the correct
amount of Tek Screws.
3. Kickers
Number
Project Location
Description
Pass Fail Open Item
Observations
Kickers are installed per Installation
3.1
Manual.
4. Hat Channel
Number
Description
Pass Fail Open Item
Observations
Hat Channels are installed per
4.1
Installation Manual.
Spacing between Hat Channels is
4.2
correct.
5. Module Installation
Number
Description
Pass Fail Open Item
Observations
All module hardware is installed per
5.1
manufacturer requirements
Send completed checklist to PVcobra within 7 days of project completion.
Name of Inspector
Date
Signature