INSTALLATION MANUAL FOR TERRAFARM SOLAR RACKING SYSTEM TerraFarm Features - ETL Classified to UL2703 Custom Engineered to Exceed Applicable ASCE, IBC, and UL Standards Electrically Bonded System 30 Amp Maximum Fuse Rating Maximum Clear Span of 40 Feet Compatible with any Listed Module with Mounting Flanges Between 1.5mm and 6.0mm Thick Landscape Orientation Maximum Capacity of PV Modules: - 12 High x 12 Wide (144 Panels) - THIN FILM (21 -26 X 47 -51 ) - 7 High x 10 Wide (70 Panels) - 54 CELL (37 -41 X 56 -60 ) - 7 High x 9 Wide (63 Panels) - 60 CELL (37 -41 X 63 -67 ) - 7 High x 8 Wide (56 Panels) - 72 CELL (37 -41 X 75 -79 ) 2013 by TerraSmart, LLC. All Rights Reserved 9200 Estero Park Commons Blvd, Suite 7 | Estero, FL 33928 Phone: 239.362.0211 | Fax: 239.362.0568 [email protected] | www.terrasmart.com REV: 3/10/2014 1 2013 TERRASMART, LLC. Introduction: The TerraFarm Ground Mount Solar Racking System is custom engineered and designed to meet nearly any structural loading requirements and was specifically designed to work in conjunction with ground screw foundations, which are professionally installed by TerraSmart. Each ground screw foundation has been designed and engineered to transfer the loads from the superstructure to the ground and have a telescoping feature that allows the vertical post to slide within the body of the ground screw, allowing for easy, infinite height adjustment of the legs, within the tolerances noted in the Approved Project Specific Engineering/Construction Plans. Each vertical post features a custom top plate connection that gives the rack simple, infinite longitudinal adjustment at the connection between the top of the vertical post and longitudinal beam. For added stability and increased loads, a proprietary telescoping lateral brace is used with a special incremental hole and slot pattern that allows for intuitive, infinite adjustment between its minimum and maximum lengths. Each purlin is custom engineered to accept virtually any Listed PV module and features slots that meet perfectly with the pre-punched holes in the mounting flange of the PV module frame, allowing for an electrically bonded, drop-in bolt connection. The purlins are slotted on the underside for maximum adjustment in the connection to the longitudinal beam and are easy to square and prepare for mounting PV modules. The TerraFarm racking system is capable of accommodating nearly any PV module available at this time, specifically Listed PV modules with mounting flanges between 1.5mm and 6mm thick. Each TerraFarm racking system is designed to meet or exceed applicable ASCE, IBC, and UL standards and has a maximum allowable clear span of 40 feet and a maximum fuse rating of 30A. Because each racking system is subjected to differing loads and/or panel specifications, structural and mechanical components may vary slightly from one rack to another. Installer Responsibility Checklist: - Comply with all applicable local, state, and national building codes and laws, including any that supersede this manual. - Procure all required permits prior to installation and ensure that component design parameters are not exceeded. - Provide appropriate method of direct-to-earth grounding in accordance with the latest edition of the National Electric Code (NEC), including NEC 250: Grounding and Bonding and NEC 690: Solar Photovoltaic Systems - Use only parts supplied by TerraSmart specifically designed for use with the TerraFarm. - Ensure PV modules are physically compatible with the dimensions of the TerraFarm prior to installation. PV modules vary between brands, models, and date of manufacture; each TerraFarm Rack is custom designed to accommodate the dimensions of the PV module as specified by the client. - Inspect the quality of the ground screw installation and that the foundations are within acceptable tolerances, as defined in the Approved Project Specific Engineering/Construction Plans. - Upon delivery of materials, inspect all packages and refuse any that contain damaged parts. Take an inventory of all delivered parts to ensure that all required parts are in your possession. - Follow the steps outlined in this installation manual and notify TerraSmart within 48 hours of delivery of any missing or defective parts or any other concern with regards to the installation process, including conflicts between this installation manual and codes, regulations, laws and/or other documentation. Note: Failure to comply with these responsibilities will void the product warranty, may have legal implications, and may make it impossible for TerraSmart to replace defective, damaged, or missing parts. 2 2013 TERRASMART, LLC. Required Tools: Sockets - 7/16", 9/16", and 8mm hex key Socket Wrench/Impact Driver Torque Wrench Adjustable Wrench Pipe Wrench Tape Measure - 100' and 35' Locking Pliers Permanent Marker/Soapstone Level - Digital Angle Finding Level and Magnetic Level String Line & Stakes Cold Galvanization Compound for repairing exposed steel after installation Supplied Hardware: TerraSmart supplies hot dip galvanized steel hardware for the structural components of the TerraFarm Racking System and stainless steel hardware for PV modules. Minimum Torque Values: 1/4" Hardware = 12 ft-lb 3/8" Purlin U-Bolt Hardware = 7 ft-lb (On each leg) *Due to varying tolerances in torque wrenches, installers should take special care on this fastener to torque the nut such that the lock washer is set but not deform the purlin. 3/8" Hardware = 15 ft-lb M16 Set Screw = Finger Tight Plus 3 Full Revolutions M16 Jam Nut = 40 ft-lb Customer Support: TerraSmart makes every effort to ensure your TerraFarm assembly is quick and easy to install. If you need assistance at any point during your installation or have suggestions on how we can improve your experience, please contact us. COMPONENTS LIST LONGITUDINAL BEAM GROUND SCREW TELESCOPING LATERAL BRACE REAR LEG FRONT LEG PURLIN 3 2013 TERRASMART, LLC. HARDWARE LIST Stainless Steel PV Panel Mounting Hardware 1/4" - 20 x 1" Hex Tap Bolt, External Tooth Lock Washer, Flat Washer, Lock Washer, and Hex Nut Hot Dip Galvanized Steel Tension Band Hardware 3/8" - 16 x 1-1/2" Carriage Bolt, Lock Washer, and Hex Nut Hot Dip Galvanized Steel Lateral Brace Hardware 3/8" - 16 Hex Bolt, Lock Washer, and Hex Nut Hot Dip Galvanized Steel U-Bolt 3/8" - 16 U-Bolt, two Flat Washers, two Lock Washers, and two Hex Nuts (Not to Scale) Hot Dip Galvanized M16 Set Screw Hardware M16 x 40 Set Screw, and M16 Jam Nut 4 2013 TERRASMART, LLC. HARDWARE LIST Cross Brace Assembly 3/16" - Galvanized Steel Wire and Galvanized Steel Wire Rope Clips (Not to Scale) 3/16" x 6" Hot Dip Galvanized Turnbuckle (Not to Scale) Galvanized Z-Purlin Washer Plate (Not to Scale) Hot Dip Galvanized Brace Clamp (Not to Scale) 5 2013 TERRASMART, LLC. STEP 1: INSERT THE LEG INTO THE GROUND SCREW SHANK. POSITION THE LEG SUCH THAT THE DISTANCE FROM THE TOP OF THE LEG TO SURROUNDING GRADE MATCHES THE PROVIDED DIMENSION ON THE CONSTRUCTION PLANS. INSERT THE SET SCREWS INTO THE PRE-WELDED NUTS ON THE GROUND SCREW AND TORQUE TO 40 FT-LB. INSTALL THE JAM NUTS ON THE SET SCREWS AND LEAVE FINGER TIGHT. REPEAT THIS PROCESS FOR THE REMAINING LEGS, ENSURING THAT THE CROSS SLOPE BETWEEN THE FRONT LEGS IS APROXIMATLEY EQUAL TO THE CROSS SLOPE OF THE REAR LEGS. A C B HE CO IGHT NS TR FRO P L U CT I M AN O S N SET SCREW 40 FT-LB GRADE BELOW GRADE INSERT LEG ASSEMBLY INTO GROUND SCREW SET HEIGHT BASED ON CONSTRUCTION PLANS JAM NUT FINGER TIGHT TIGHTEN THE SET SCREW FOLLOWED BY THE JAM NUT ALL LEGS INSTALLED 6 2013 TERRASMART, LLC. STEP 2: INSTALL CLAMP ON THE REAR LEG AND BOLT THE LATERAL BRACE INTERNAL TUBE TO THE CLAMP. SLIDE THE EXTERNAL TUBE OVER THE PREVIOUSLY INSTALLED INTERNAL TUBE AND SECURE THEM TO THE FRONT LEG WITH ANOTHER CLAMP. BOLT THE INTERNAL AND EXTERNAL TUBES BY ALIGNING THE HOLES IN EACH TUBE. THE INTERNAL TUBE HAS MULTIPLE BOLT HOLES FOR EASIER ON-SITE ALIGNMENT. REPEAT FOR THE REMAINING LATERAL BRACES. NOTE: REFER TO CONSTRUCTION PLANS AS IT MAY BE NECESSARY TO INSTALL ONLY THE DIAGONAL LATERAL BRACE. LEAVE ALL HARDWARE FINGER TIGHT. A CLAMP E C SLIDE INTERNAL TUBE EXTERNAL TUBE SLIDE SLIDE EXTERNAL BRACE TUBE OVER INTERNAL BRACE TUBE D INSTALL CLAMPS ON REAR LEG LATERAL BRACE BOLTS B CARRIAGE BOLTS INSTALL INTERNAL LATERAL BRACE TUBES AND BOLTS INSTALL CLAMPS ON FRONT LEGS AND BOLT TO EXTERNAL LATERAL BRACE TUBE BOLT LATERAL BRACES BY ALIGNING HOLES ALL LATERAL BRACES INSTALLED 7 2013 TERRASMART, LLC. STEP 3: INSTALL THE FRONT LONGITUDINAL BEAM BY PLACING IT ON TOP OF EACH OF THE FRONT LEGS. USE PROVIDED U-BOLTS TO LOOSELY SECURE THE BEAM TO THE LEG. CENTER THE BEAM BETWEEN THE TWO LEGS BY MEASURING EACH CANTILEVER TO ENSURE THEY ARE EQUAL. INSTALL THE REAR BEAM USING THE SAME PROCESS AS ABOVE. WITH BOTH BEAMS IN PLACE TAKE CENTER TO CENTER AND DIAGONAL MEASUREMENTS FROM EACH CORNER TO VERIFY THE TWO BEAMS ARE PARALLEL AND SQUARE. LEAVE HARDWARE FINGER TIGHT. A B LONG BEAM L UA EQ LIVER E NT CA U-BOLT L UA R EQ LIVE E NT CA FRONT LEG PLACE LONGITUDINAL BEAM ON LEGS AND LOOSELY INSTALL ALL U-BOLT HARDWARE CENTER THE BEAM BETWEEN THE TWO LEGS TO ENSURE THE CANTILEVER IS EQUAL ON BOTH SIDES C EQUAL DIAGONALLY EQ UA T O L CEN CE T E R NT ER EQ UA T O L CE N CE N T E R TE R INSTALL THE REMAINING REAR LONGITUDINAL BEAM AND TAKE CENTER TO CENTER AND DIAGONAL MEASURMENTS. ADJUST FRONT AND/OR REAR LONGITUDINAL BEAM UNTIL THEY ARE EQUAL. LEAVE ALL HARDWARE FINGER TIGHT. BOTH LONGITUDINAL BEAMS INSTALLED 8 2013 TERRASMART, LLC. STEP 4: INSTALL CROSS BRACE BY CLAMPING AN EYELET TO TOP OF REAR LEG. CLAMP TURNBUCKLE TO BOTTOM OF OPPOSITE REAR LEG. REPEAT FOR OTHER CROSS BRACE TO FORM AN "X." NOTE: EXTRA MATERIAL IS SUPPLIED WITH THE PRE-FABRICATED CROSS BRACE ASSEMBLY AND MAY REQUIRE PRE-TENSIONING BY LOOSENING WIRE ROPE CLIPS AND PULLING THE LOOSE END TAUGHT. RE-TIGHTEN WIRE ROPE CLIPS. ROTATE TURN BUCKLE BODY, WHILE PREVENTING THE EYELET ATTACHED TO THE WIRE ROPE FROM ROTATING, UNTIL THE CROSS BRACE ASSEMBLY IS TAUGHT. A B C WIRE ROPE CLIPS REAR LEG WIRE ROPE PREVENT EYELET FROM ROTATING WHILE TIGHTENING TURNBUCKLE CLAMP TURNBUCKLE WIRE ROPE CLAMP TURNBUCKLE ROTATE TURNBUCKLE TO TIGHTEN CARRIAGE BOLT WIRE ROPE CLIPS CLAMP REAR LEG CARRIAGE BOLT INSTALL CLAMP ON THE REAR LEG AND BOLT THE CROSS BRACE TO THE CLAMP INSTALL A CLAMP ON THE OPPOSITE LEG AND SECURE THE FREE END OF THE CROSS BRACE TO THE CLAMP REPEAT PREVIOUS STEPS FOR THE OTHER CROSS BRACE AND TIGHTEN THE TURNBUCKLE ON EACH BRACE BOTH CROSS BRACES INSTALLED 9 2013 TERRASMART, LLC. STEP 5: INSTALL Z-PURLINS ON TOP OF LONGITUDINAL BEAMS BY LAYING OUT THE Z-PURLINS PER THE CONSTRUCTION PLANS. FASTEN EACH Z-PURLIN TO THE LONGITUDINAL BEAMS WITH U-BOLTS AND WASHER PLATES. STRING LINE THE BOTTOM EDGE OF THE Z-PURLINS TO ENSURE THEY ARE ALIGNED. CHECK THE TILT ANGLE AND FRONT EDGE CLEARANCE AGAINST CONSTRUCTION PLANS AND ADJUST AS NECESSARY. TORQUE ALL PREVIOUSLY INSTALLED BOLTS TO THE TORQUE SPCIFICATIONS PROVIDED ON PAGE 3. A MIRRORED A END OF BEAM TO FIRST U-BOLT MIRRORED B DISTANCE BETWEEN U-BOLT PAIRS C DISTANCE BETWEEN ADJACENT U-BOLTS B C REPEAT PATTERN LOCATE DIMENSIONS A,B AND C ON CONSTRUCTION PLANS AND LAYOUT Z-PURLINS AS SHOWN. IN THE EVENT OF A CONFLICT, A Z-PURLIN MAY BE INVERTED. IF A Z-PURLIN IS INVERTED THE OPPOSITE PURLIN IN THE PAIR MUST ALSO BE INVERTED SUCH THAT THE TWO Z-PURLINS SUPPORTING A COLUMN OF PANELS ARE MIRRORED TO EACH OTHER. C B Z-PURLIN WASHER PLATE CHECK TILT ANGLE U-BOLT STRING LINE HERE TO ENSURE Z-PURLINS ARE ALIGNED ADJUST LEG WITHING PROVIDED TOLERANCE ADJUST LATERAL BRACE WITHIN TOLERANCE 7 FT-LB LONGITUDINAL BEAM FASTEN Z-PURLIN TO LONGITUDINAL BEAM WITH U-BOLT AND WASHER PLATE. TORQUE TO 7 FT-LB ON EACH LEG ADJUST LEG WITHIN PROVIDED TOLERANCE GRADE . CHECK FRONT EDGE HEIGHT CHECK THE TILT ANGLE AND FRONT EDGE CLEARANCE AGAINST CONSTRUCTION PLANS AND ADJUST LEGS AND LATERAL BRACES, WITHIN PROVIDED TOLERENCES. ALL Z-PURLINS INSTALLED 10 2013 TERRASMART, LLC. STEP 6: INSTALL PV MODULES TO Z-PURLINS BY INSERTING THE MOUNTING HARDWARE THROUGH FOUR PRE-PUNCHED HOLES IN THE PV MODULE FRAME AND Z-PURLIN. Z-PURLINS ARE PRE PUNCHED TO MATCH THE MOUNTING HOLE LOCATIONS ON THE PV MODULE FRAME. ONCE ALL HARDWARE IN INSTALLED AND RACK IS ERECTED SATISFACTORILY, TORQUE ALL REMAINING HARDWARE TO SPECIFICATIONS ON PAGE 3 AND TOUCH UP ANY BLEMISHES IN THE STEEL WITH COLD GALVANIZING COMPUND TO PREVENT RUSTING. B A PV MODULE FRAME PV MODULE FRAME MOUNTING HARDWARE PV MODULE BACK SHEET (DO NOT DAMAGE) PV MODULE MOUNTING HOLE PRE PUNCHED Z-PURLIN MOUNTING HOLE LONGITUDINAL BEAM Z-PURLIN Z-PURLIN BOLT PV MODULE FRAME TO Z-PURLIN AS SHOWN PV MODULE MOUNTED TO Z-PURLINS. ALIGN MOUNTING HOLES AND BOLT PV MODULE FRAME TO Z-PURLIN. (BOTTOM VIEW) ALL PV MODULES INSTALLED 11 2013 TERRASMART, LLC. TERRATRAY INSTALLATION: EACH TERRAFARM RACK TYPICALLY REQUIRES TWO STICKS OF TERRATRAY PRE-CUT TO APPROXIMATELY HALF OF THE EAST-WEST LENGTH OF THE RACK. DETERMINE THE NORTH-SOUTH LOCATION ON THE PURLIN WHERE THE TERRATRAY IS TO BE INSTALLED. ALIGN THE EDGE OF THE TERRATRAY WITH THE OUTER EDGE OF THE PANEL AND LEAVE A TYPICALLY 4" GAP BETWEEN THE STICKS AT THE CENTER OF THE RACK. SECURE THE TERRATRAY WITH PROVIDED SELF TAPPING SCREWS AT EACH PURLIN ENSURING THE TERRATRAY IS NOT LEVEL TO ALLOW FOR WATER DRAINAGE. B A TERRATRAY 4 in GAP (TYP) ALIGN TERRATRAY WITH EDGE OF PANEL A TERRATRAY DISTANCE ESTABLISHED BY OTHERS PANEL GRADE TERRATRAY ESTABLISH THE LOCATION OF THE TERRATRAY. POSITION TERRATRAY SUCH THAT THE ENDS ARE APPROXIMATELY ALIGNED WITH THE OUTER EDGE OF THE PANEL AND THAT THERE IS A TYPICAL 4" GAP BETWEEN TERRATRAYS. C TERRATRAY PURLIN (TYP) SELF TAPPING SCREW AT EACH PURLIN (TYP) SECURE THE TERRATRAY TO THE RACK WITH A SELF TAPPING SCREW AT EACH PURLIN. ENSURE THAT THE TERRATRAY MAINTAINS A 0.1 MINIMUM SLOPE TO ENSURE PROPER DRAINAGE. NOTE: TYPICAL INSTALLATIONS WILL LIKELY HAVE AN E-W PITCH ALREADY IN THE RACK AND NO SPECIAL CONSIDERATION WILL BE NECESSARY. AMDT 2013 TERRASMART, LLC.
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