Installation Manual for WS WindSafe Roof-Top Rack System for Flat Roofs (JBH5154_FotoFlexer) R:/Marketing/Product Pictures/WS Installation Manual Draft 12-22-10 1. Disclaimer 2. General Rack Description 3. Tools 4. Example 5. Sample Drawing 6. Installation Instructions 7. Component Details 8. Tolerances 9. Examples
1. Disclaimer: The installer of each system and/or the contractor or developer of each project shall be responsible and liable for safe and proper installation of each system, and also to initiate, maintain and supervise all OSHA and safety programs and precautions for each project and project site, and to provide all required protection to prevent damage, injury, loss or death to any or all persons, property and work present or located on the project site. Schletter Inc. does not install any portion of its mounting systems and therefore will not have, and hereby specifically disclaims, any duty or responsibility for safe and proper installation of any mounting system or jobsite safety as to any jobsite where installation of any of its mounting systems occurs. Please follow the drawings, and report any issues or discrepancies to Schletter. 2. General Rack Description: The Flat-Roof WS System is designed and engineered for your PV-System and site location. The design and structural calculations of the rack determine the corresponding profiles and the required ballast that stabilize the roof-mounted PVsystem. Note: module orientation is either Horizontal / Landscape or Vertical / Portrait orientation. These determine rail and module clamp placement. NOTE: Schletter aluminum framing systems are not anodized. NOTE: THE DRAWINGS IN THIS MANUAL ARE NOT THE DRAWINGS FOR YOUR RACK ORDER. THESE ARE EXAMPLES AND ARE GENERAL INSTRUCTIONS FOR MOUNTING WS SYSTEMS. Planning: Drawings and parts list are prepared previous to rack system delivery. The drawing dimensions describe and detail the pre-assembled systems and individual components that will be assembled on the job site. Included are components, adjacencies and attachments. BEFORE YOU BEGIN DELIVERY OF YOUR RACK: The Customer is responsible to Count and account for Verification on Delivery of the materials. Please Count: - number of Pallets of Rails - number of rails on each Pallet - number of pre-assembled triangles - number of boxes of parts and hardware - content and number of all parts and hardware contained - content and number of miscellaneous other items ONCE YOU BEGIN: During your assembly, if unexpected situations happen and the rack does not fit the drawing layout. DO NOT ADJUST THE RACK without calling Schletter first. General contact phone number for Schletter Inc. is: (520) 289-8700, or call your Salesman, who is the Project Manager on your System.
3. Tools you will need: - 6mm Allen Hex wrench and/or Star-head torque (for module clamps and triangle assembly bolts) - 8mm socket for various hex-head elements - 13mm wrench or socket (for triangle assembly nuts & M8 lag screws) - 15mm wrench or socket (for M10 flange nuts on standoffs and ballast trays & M10 lag screws) - 17mm wrench or sockets (for M10 machine bolts only on ballasted systems) (Tool List USA.pdf)
4. Example: The layout below is a Horizontal / Landscape mounting system for general installation. A drawing sheet of this racking system follows. The Main parts of a WS Windsafe System are: 1. Pre-assembled Triangle Support bolted to a Support Rail with hardware provided for strut attachments. 2. Purlin rails to hold Clamps for the panels 3. End Module clamps & 4. Middle Clamps for Item 7 Solar Panels. (By Others: i.e. Solar Installers) 5. SolTub Trays to hold ballast (ballast provided by installer) with hardware, or an alternate attachment to the roof structure. (Other fixation elements could be used if the roof cannot support ballast material for SolTubs.) 6. Windshot panels to deflect the wind. 7. Solar Panels (By Others: Solar Installers) (v1.ws 2hx4 30 Green Choice H- 4 piece)
5. Sample Drawing: (NOTE: Ballast material is Not Included; ballasting will be by Installer.) The following drawing is a sample; your drawing will look similar. Since there are various WS configurations, the Installation Instructions will show differing triangle racks to demonstrate general installations. (Sheet WS 2Hx4 20 )
6. Installation Instructions: Step 1: Unpack all of the assembly and parts you have received. You have already verified your shipping order. A. Preassembled Triangle Top (Parts, components and assemblies): Take the top support portion of the triangle. Unfold the struts. The Bolt/nut assemblies and Struts are already assembled. KlickTop components are in place on the top Support rail. KlickTops will be adjusted as shown per drawing dimensions when purlin rails are set. (F-Pre Assembled Triangle Top) (F-Purlins to Triangles) B. Base Beam for Preassembled Triangle with connection hardware is bolted at front. (F-Base beam w hardware)
C. You will bolt the triangle top struts to the base beam, which is already assembled at the front bolt. Attach the struts to the bottom rail using the M8x55 nut/bolt assembly. Tighten by hand, then torque to the required strength per the drawings. Note: there is a washer on either side of the rail between the nut and rail and the bolt and rail. (Support Triangle Explode) (F-Bolt to Base rail) (F-DSC06653) D. Assembled Triangle: (Support Triangle for WS 2Hx3-Tub)
6. Installation Instructions (Continued): Triangle to Ballast Tub Step 2: A. Place the Soltubs squared, per dimensions on the drawings on a mat, supplied by others, to protect the existing roofing membrane. (F-SolTubs to Matts) Step 3: B. Attach the bottom rail to the Soltubs with the nut/bolt assembly (Items 9, 10, 11, 12). An M10 Hex Head bolt goes through a pre-cut hole in the bottom of the triangle rail through the Soltub. Next a No-slide plate is placed under the soltub and secured with an M10 Flange Nut from the bottom. (F- Triangles to Tub Detail) (F-Triangles to Tubs) (F-Parts List)
6a. Installation Instructions, Alternate (Continued): Triangle to Stand-Offs, Bolted/Screwed to Structure below roof deck Step 2a: A. Place the assembled Triangle on the Stand-Off Assembly (8). Secure with screws (10) onto the roof deck to the structural joists below (provide flashing, to protect the existing roofing membrane per roofing industry standards as provided by others). (WS 2H x 3 20 w StOs-1-1) Step 3a: B. Continue assembling rack as per the following Installation Instructions. (WS 2H x 3 20 w StOs-1-2) (WS 2H x 3 20 w StOs-1-1)
6. Installation Instructions (Continued): Purlin Rails to KlickTop Step 4: A. Attach the purlin cross rails (13) in the KlickTop Components (3) on the top rails of the support triangles. Adjust the KlickTops to the placements of the rails as dimensioned on the drawings. Tighten the KlickTop with a 6mm hex key Allen wrench as shown in the photo. Verify the dimensions of placements of the Klick components with the drawings. The Purlins will cantilever equally over the support triangle at each end. Verify with the drawings. (F-Purlins to Triangles) (F-KlickTop Purlin Install) (F-DCS07745C)
6. Installation Instructions (Continued): Schletter solar mounting systems Step 5: Place the module clamp Assemblies. The module clamps will come in separate parts. This is if you are installing the typical Click-in components and module clamp. (Request separate document: Step 8: Component Details Connecting screws and nuts.) 1. Insert the green click component in the channel of the pre-formed Schletter rail. Insert the M8 nut with the tapered edges in the down direction. Push down with slight effort. Click it in so it is level. (DSC08628a) (DSC08629a) 2. Place a grounding plate (when required) which inserts with tabs for a Portrait installation. If you have a Landscape installation, contact Schletter Inc. for direction. The Module mounting clamp is then placed with a M8 hex head mounting bolt and serrated washer through the clamp. Hand tighten the bolt with an Allen wrench, do not completely torque, before the Module panel is installed. (DSC08630a) (DSC08640b)
6. Installation Instructions (Continued): Schletter solar mounting systems Step 5a: (Alternate) Rapid 2+ Grounding Module Clamp If you are using the Rapid 2+ Module Clamp with a stainless steel grounding spike on each side of the Middle Clamp, this will ground the Modules on either side. End clamps do not need grounding spikes if you have middle clamps with spikes on one side. Place the module clamp Assemblies. 1. Place the Rapid 2+ into the channel of the Schletter rail. Next place the M8 mounting bolt as shown below. The Module mounting clamp is then placed with a M8 hex head mounting bolt and serrated washer through the clamp. Hand tighten the bolt with an Allen wrench, do not completely torque, before the Module panel is installed. (DSC08615) (DSC08590) (F-DSC08623a)
6. Installation Instructions (Continued): Schletter solar mounting systems Step 6: Mounting the Module is by a certified licensed PV Installer Only. Refer to your Panel manufacturer s Installation Guide for specifics of the Module installation. (F-DSC06475a) Wiring and module installation are not in the realm of Schletter, Inc. If the modules are placed correctly (refer to drawings), there should be a 5mm gap between each module edge horizontally for Portrait layouts, and vertically for Landscape layouts. A 23mm gap includes the clamp in the other direction.
6. Installation Instructions (Continued): Schletter solar mounting systems Step 7: Attach the corrugated Windshot panels. See Component Details: 7.10 Wind Deflector: Winshot (following), use 2 Ejots (self-drilling metal screws) at each support rail for a 440871-M (160mm) winshot, 3 Ejots for 440871-M (250mm) winshot, and 3 Ejots for 440871-M (500mm) winshot. When more than two supports are used, the windsafe panels will overlap at each inside or center triangle. Note: as in the Detail A, all 3 types of Winshots are used. The horizontal overlapping of each of the 3 types allows for movement to prevent the Ejots from shearing off. The same Ejot can be shared where Windshots overlap horizontally. (v1ws2hx4 30 -Green Choice-HP 2 Wishot.tiff or jpg) 7. Component Details: Connecting screws and nuts (Request separate Brochure)
7. Component Details: Profile Overview Soltubs are the standard ballast trays for a Wind Safe. Schletter has other types of attachments for specific roof situations. 7.1 SolTub (Ballasted Tray) 7.2 SolTub End Cover (as needed) 430752 430753 430754 430752-D 430753-D 430754-D SolTub2 SolTub3 SolTub4 CoverPlates: SolTub 2 SolTub 3 SolTub 4 7.3 Stand Off: 3'', 4'', 8'', 12'' 7.4 Fix 2000 or Vario Fix-V Assembly 400871 3, - 4, - 8, - 12 400878-FixT 400873 - Fix2000 113009-001 VarioFixV Standoffs for Roof Structure Attachment for Hanger Bolt with EPDM & Ejots (shown 4 & 8 ) attachments Anchoring for trapezoid sheet metal roofs 7.5 Base Beams for Pre-assembled Triangle 7.6 Struts 430910-G 430940-G 430763-M Base-Beam Light Base-Beam Profi Strut 30x3 7.7 Support Beams / Top Rail for Pre-assembled Triangle 7.8 KlickTop 911000-214 Profi Support Beam 911000-215 Light Support Beam 430520 M8 Support Beams are installed with KlickTop Mounts 430520 M8 KlickTop Assembly KlickTop Components allow faster mounting with flexible movement along the rail with Nose
7.8 Crossbeams / Purlins 430071 430070 430010 430015 440520 430071 430070 430010 430015 440520 Eco05 Solo05 Profi 05 ProfiPlus KP-WS 7.9 Module Clamps: are adjusted for Module thickness with pre-assembled bolt & click 400420-400230- 131001-, (430811-50), 131003-497482KP-EcoEndClamp 497480KP-EcoMidClamp 400451 M20-35 28-39, 40-50 (Old # s) 28-39, 40-50 With Gasket With Gaskets End-clamp Mid-clamp End-clamps (Rapid 2+) Mid-clamps 400256 400255 400257 400258 Laminate Laminate Laminate Laminate End-clamp Middle-clamp End-clamp Middle-clamp ECO8 ECO8 ECO6 ECO 6 With flat plate and EPDM gaskets as required for Thin Film and Glass Modules. 7.10 Wind Deflector: Winshot 440871-M (160mm) 440871-M (250mm) 440871-M (500mm) Winshot deflectors are corrugated adjustable panels in 3 heights, custom cut lengths for Support widths as required.
8. Tolerances Schletter mounting systems are designed for economy to the specific snow and windloads of the installation site for the PV-system. The single components of the system are used to maximize the bearing capacity. The racking must be installed with precision to the exact drawing specifications, including splice locations and length of members. Please follow the drawings that came with your rack specification. Variations from the mounting plans can cause structural overstraining. Therefore, it is very important to keep within following tolerances: Cantilever Support Distance Tolerances: Distance of Supports: ± 2.165 inch Cantilever: ± 1.181 inch Module inlay in the clamp: - 0.0787 inch Above is a 497480 KP Eco Mid Clamp on a 440520 - KP-WS rail.
9. Examples:The following sets of sheets are both typical and atypical installation examples of WS Systems. (Note: These drawings are for descriptive of examples of a WS - Windsafe System. They might look similar to your system, but are NOT the drawings that you will be installing.) 1. (WS 1Vx 9 15 ) 1 Vertical row by 9 panels at 15 tilt PV system: This system is a simple triangle with one strut. It has the KlickTop Component mounting system assembly on the top triangle support to allow ease and adjustability when mounting the cross rail to support the modules. The KlickTop is the current standard at Schletter. Ballast materials for SolTubs are provided by Installer. (WS 1Vx9 15 )
2. (WS 2Vx 4 20 ) 2 Vertical rows by 4 panels at 20 tilt PV system: This system s triangle has 3 struts to support the top rail. In lieu of Soltub Ballast trays, the triangles are clamped on a DN support rail, which is bolted to 4 Standoffs screwed through the roof deck to the structure below. (WS 2Vx6 20 SO nvtr)
3. (WS 3H x 7 15 ) 3 Horizontal rows by 7 panels at 15 tilt PV system: This system is a Landscape (Horizontal) System on a DN support rail, which is bolted to 4 Standoffs screwed through the roof deck to the structure below. (WS 3H x 7 15 -R)