Install Manual GC Standing Seam Roof System Rail Seam Mount CONTENTS I II III IV V VI VII VIII IX GENERAL MATERIALS AND TOOLS REQUIRED SYSTEM COMPONENTS INSTALLATION OF SYSTEM SYSTEM OVERVIEW MATERIALS AND WARRANTY SAFETY PRECAUTIONS AND RESPONSIBILITY OF INSTALLER ROOF AND LAYOUT PLANNING PREVENTATIVE MAINTENANCE
I General The GameChange Solar Standing Seam System ( Standing Seam System ) is designed to be installed on flat or sloping roofs, and is tested and engineered to withstand wind, seismic and snow load to specification when properly installed according to the installation manual. The installation manual must be precisely followed to ensure a proper installation of the Standing Seam System; otherwise there may be a decrease in the installation performance and a voiding of the warranty. II Materials and Tools Required The following tools are required for the installation of the Standing Seam System: 1.0 7/16-inch drivers, sockets and wrenches for 1/4-inch hex bolts 2.0 9/16-inch drivers, sockets and wrenches for 3/8-inch hex bolts 3.0 3/16 Allen drivers for 1/4-inch and 3/8-inch set screws 3.1 For torque settings for metals other than 22 and 24 ga steel please contact GameChange. 4.0 String Line 5.0 Roof marking tool (chalk, crayon, paint pen) 6.0 Tape Measure 7.0 Jig (sized to panel and panel and inside dimensioned panel mounting holes plus ¼ inch spacing) for spacing. Rev. 3-11-2016 GameChange Standing Seam Roof System Install Manual Rail Seam Mount 2
III System Components The Standing Seam System contains the following parts. Separate parts list with part quantities will be available for each project. Seam Clamp (GC71) Rail (20 ft. long) (GC72) L Foot (GC73) Panel Clip Mid (GC315T) Panel Clip End (GC314T) Jumper Strap (GC120) Wire Management Hook (optional) (GC76) Hardware o Panel mounting hardware - stainless steel 1/4-20-inch x 1 3/4 to 2 ½ inch T bolts 1/4-20-inch serrated flange nuts o Rail mounting hardware 3/8-16-inch x 1 inch carriage bolt or t bolt - magnicoat steel 3/8-16-inch serrated flange nuts - magnicoat steel 1/4-20-inch x 3/4 serrated head flange bolt or ¾ inch hex bolt with lock washer - stainless steel 1/4-20-inch x 1 1/4 serrated head TEK 5 screws - magnicoat steel o Seam Clamp mounting hardware - stainless steel 3/8-24-inch x 3/4 set screw (oval tip, Allen) Rail (GC72) Jumper Straps (GC120) Jumper Strap installed on Rail L Foot (GC73) Panel Clip Mid (GC315T) Panel Clip End (GC314T) Seam Clamp (GC71) Rev. 3-11-2016 GameChange Standing Seam Roof System Install Manual Rail Seam Mount 3
IV Installation of System Step 1: Attachment of Seam Clamps 1.0 Measure the footprint of the array according to the installer s design and site plan. 2.0 Find the edges of the array according to provided design. 3.0 Mark lines on roof for the edges of array. 4.0 Make north south spacer jig the length of the module being used + ¼-inch. 5.0 Mark the jig with the locations of the mounting holes on the back of the module. 6.0 This will establish the locations of Rails which run east-west. 7.0 Please jig so that it runs from very north-west corner to the south of that location. 8.0 Locate first seam at first mark on jig at between 4 and 15 inches to the east of that location. 9.0 Attach first Seam Clamp at this location 9.1.1 Place seam clamp over seam. 9.1.2 Attach set screw using driver. 9.1.3 Torque to specification. 10.0 Attach Seam Clamps every other seam (unless directed otherwise by GameChange) to the end of the first 20 ft and 1/2 inch (length of rail plus extra space for thermal expansion) to the east, starting from the western edge of array. If there is not a Seam Clamp within 18 inches of the end of a Rail, then attach a Seam Clamp to the seam nearest the end of that Rail location. Rev. 3-11-2016 GameChange Standing Seam Roof System Install Manual Rail Seam Mount 4
11.0 Measure starting from the west every 20 ft (length of rails) plus 1/2 inch space for thermal expansion for next Rail. 12.0 Attach Seam Clamp to first Seam within 18 inches. 13.0 Attach Seam Clamps to every other seam (unless otherwise directed by GameChange) until reach end of Rail location. 14.0 Attach Seam Clamps every other seam (unless directed otherwise by GameChange) to the end of the first 20 ft and 1/2 inch (length of rail plus extra space for thermal expansion) to the east, starting from the western edge of array. If there is not a Seam Clamp within 18 inches of the end of a Rail, then attach a Seam Clamp to the seam nearest the end of that Rail location. 15.0 Repeat 12 through 14.0 until east end of array. 16.0 Make sure to attach extra Seam Clamp if there is not one within 15 inches of easternmost end of Rail locations. 17.0 Repeat 8.0 through 16.0 from next location on jig. 18.0 Repeat 8.0 through 17.0 until south end of array. Rev. 3-11-2016 GameChange Standing Seam Roof System Install Manual Rail Seam Mount 5
Step 2: Attachment of Rails 1.0 Attachment of the L Feet 1.1 Place L Foot above Seam Clamp 1.2 Attach with 1/4-20-inch serrated flange bolt or Hex bolt and lock washer 1.3 Torque to specification. 1.4 Repeat 1.1 to 1.3 until array is completed 1.0 Attachment of the Rails 1.1 Place Rail next to L Foot 1.2 Insert carriage bolt or T bolt into Rail 1.3 Put bolt through L foot 1.4 Attach with serrated flange nut 1.5 Torque to specification 1.6 Repeat 1.1 through 1.5 until Array is completed. 1.7 Rails may be cut in the field to complete array if 20 ft lengths do not enable proper completion of array. Make sure to follow Seam Clamp location instructions for all Rails regarding location of Seam Clamps within specified distances from ends of Rails. There must always be a minimum of 2 Seam Clamps used per Rail. Rev. 3-11-2016 GameChange Standing Seam Roof System Install Manual Rail Seam Mount 6
Step 3: Wire Management 1.0 Install optional Wire Management Hooks by simply inserting T shape into 3/8-inch slot on side of rail and then rotating clockwise until Wire Management Hook locks in vertical position. 2.0 Wire Management Hooks may be inserted as needed and enable all east west wiring to be supported Step 4: Module Attachment 1.0 Attaching first End Clips with modules at start of Module Mounting Rail 1.1 Insert T bolts (or carriage bolt) into slots in Module Mounting Rails approximately 1/2 inch plus in from ends of Module Mounting Rails. 1.2 Place module on Module Mounting Rails next to T bolt (carriage bolt). 1.3 Place End Clips above panel making sure module is butted up against the tabs of the End Clips, and the End Clips are perpendicular to the angled surfaces of the Module Mounting Rails. 1.4 The T bolt heads should be rotated clockwise to lock perpendicularly to the slots, and the bolts should be perpendicular to the angled Module Mounting Rail surfaces and to the panels. If there is a groove on the threaded end of T bolt which is aligned with the T head, the groove should be perpendicular to the slot in Module Mounting Rail. 1.5 Fasten using flange nuts. (If using a drill or impact, stop after single click, then follow-up with a torque wrench and torque to specification.) 2.0 Attaching Mid Clips with modules 2.1 Insert T bolts (or carriage bolt) into slots next to modules. 2.2 Place module on Module Mounting Rails next to T bolt (carriage bolt). 2.3 Place Mid Clips above panel making sure modules are butted up against the tabs of the Mid Clips. Rev. 3-11-2016 GameChange Standing Seam Roof System Install Manual Rail Seam Mount 7
2.4 The T bolt heads should be rotated clockwise to lock perpendicularly to the slots, and the bolts should be perpendicular to the angled Module Mounting Rail surfaces and to the panels. If there is a groove on the threaded end of T bolt which is aligned with the T head, the groove should be perpendicular to the slot in Module Mounting Rail. 2.5 Fasten using flange nuts. (If using a drill or impact, stop after single click, then follow-up with a torque wrench and torque to specification.) 3.0 Repeat 2.1 through 2.5 using Module Mid Clips until end of Module Mounting Rail is reached. Then finish the end of the Rail installation using End Clips. 4.0 Complete entire array Rev. 3-11-2016 GameChange Standing Seam Roof System Install Manual Rail Seam Mount 8
Step 5: Grounding The modules and Module Mounting Rails are all bonded together, east and west, so that each row from one single structure as long as Grounding Strips (GC 20) or teethed Mid Clip (GC315T) are properly installed. A jumper (GameChange provided GC Jumper or WEEB-6.7) is required at one thermal expansion point between each table/set of rails (only one jumper per row of modules) on either the top or bottom rail to maintain the continuous bonding/grounding. Install WEEB-6.7 jumpers by drilling a ¼ hole and using hardware longer than 1 in length approximately 1 in from the rail edge. If using GC Jumpers, bend GC Jumper to shape as shown below to allow for a minimum of four inches of slack and install GC Jumper at same location but using 1.25 inch serrated TEK5 screws. Ultimate earth ground shall be achieved via the mounted UL 1703 Listed PV modules (as specified per corresponding installation manuals) or grounding lug (WEEBL-6.7) installed by drilling a ¼ hole and using hardware longer than 1 in length approximately 1 in from the edge of the selected Rail. GameChange recommends each one continuous bonded structure have its own bonding lead, up to 16 strings or 210 modules which ever come first may be grounded together using 8-gauge copper wire. Repeat for each 16 strings. The entire system needs to be grounded from a single point to an appropriate grounding source. **Please confirm with an electrician, as this is their responsibility** Depiction of GC Jumper Strap installation V System Overview The Standing Seam System is a simple, affordable, easily installed roof-based solar mounting system. The Standing Seam System may be installed on solar arrays of up to 100,000 solar panels each (approximately 25 MW). Maximum panel size for the system shall be 42 x 82 inches for 60 or 72 cell modules and 55 x 68 inches for 80 cell modules. VI Materials and Warranty All materials are made from non-corrosive materials, stainless steel, magnicoat steel and aluminum, with a product warranty of twenty (20) years. VII Safety Precautions and Responsibility of Installer The installer is responsible for the following: Following all instructions in this Install Manual Utilization of only qualified personnel Rev. 3-11-2016 GameChange Standing Seam Roof System Install Manual Rail Seam Mount 9
Using only GameChange parts. Using other parts to complete the installation as substitutes may void the warranty. Making sure the roof structure can support the loading resulting from the Standing Seam System Following all safety procedures as outlined in this Install manual, both for mechanical and electrical aspects. of the solar PV array installation Following all safety instructions that are required by relevant local, regional and national organizations Materials are packaged in optimal manner to protect components. Do not un-package until time of installation. Un-packaging and restacking may cause damage to components. General safety precautions: Plan for safe practice during any installation activity with respect to hazards: from tripping, falling, lifting, repetitive stress, and any overhead or electrical hazards. When working close to building roof edges, consider protection options that reduce worker exposure to fall hazards. Refer to OSHA safety guidelines. Metal components often have sharp edges. Handle carefully! Wearing gloves is good practice. This document is not prescriptive regarding safety and does not purport to address all the safety concerns that may arise with its use. Contractors should become familiar with all applicable safety, health and regulatory requirements before beginning work. Electrical safety notice The Standing Seam System is a mechanical system and contains no live parts. Mechanical installers and electricians should coordinate in order to ensure that all personnel are aware of electrical hazards that may result once panels have been placed on the racking structure. Build rate Estimated mechanical installation rate (racks and panels per day) for an array consisting of commercialclass modules installed with the Standing Seam System and assuming a well-equipped six-person crew is on the roof and working 8 hours / day with full task interchangeability: > 200 kw / week. Field modifications Unauthorized field modification of GameChange components or assemblies may affect GameChange warranty coverage. Provide marked up drawings for GameChange s review, comment and approval prior to attempting any field modifications. Work arounds Workers laying out or installing arrays on rooftops may encounter undocumented or unexpected obstacles requiring a work around. Since PV arrays are intended to be primarily regular and repeating structures, work arounds should be noted on working drawings. When a work around affects the location of two or more modules at once, the supervisor should be advised and the work around should be evaluated and then completed in a manner that ensures that the remainder of the array is not affected. Roof surface All large flat roofs have pitch and undulation, jointed assemblies, and may also have level separations and parapets. Various roof-mounted fittings, air vent pipes and equipment such as HVAC or process equipment may also be encountered. The precise location of many rooftop details is not known since such details are installed under conditions in which the worker or contractor may have discretion regarding final location. Fire Safe Roof The Standing Seam System is to be mounted over a fire resistant roof covering rated for the application. The Standing Seam System is not meant for sloped roofs where the slope is greater than 5. All regional safety requirements should be followed when installing the Standing Seam System. All equipment/tools should be properly maintained and inspected prior to use. This installation manual is intended for use by professional installers with a working knowledge of construction principles. If the install manual is not followed completely the warranty may be voided and the solar system may not operate optimally. Rev. 3-11-2016 GameChange Standing Seam Roof System Install Manual Rail Seam Mount 10
VIII Roof and Layout Planning Roof area must be properly inspected, repaired and made to like-new condition prior to installation to provide for a proper installation. All Debris must be removed from the roof area Structural load analysis must be obtained prior to roof installation to make sure that the roof will bear the load form the weight of the Standing Seam System. It is recommended that an inspection of the roof is conducted both prior to and after the installation of the Standing Seam System in order for the continuation of the roof warranty. Make sure to place the array in areas where there is no shading. Install the array facing as close as possible to south. Follow local building inspector setback rules, but in no case place panels closer than 5 feet to edge of building roof. IX Preventative Maintenance An annual inspection must be done to identify mechanical movement caused by any reason including thermal expansion and contraction or wind. An inspection should also be done after all storms with severe winds (over 80% of design wind speed). Inspect clips and torque settings on all hardware and make sure their installation and torque settings remain correct or are corrected. All Clips must be checked to make sure there is no gap between side of Clip and module. It is estimated that two qualified laborers should be able to properly inspect and maintain racking for approximately 1,000 panels per day. Proper preventative maintenance must be conducted or warrantee may be voided. Rev. 3-11-2016 GameChange Standing Seam Roof System Install Manual Rail Seam Mount 11