SolarWorld Sunfix Grount Mount Tilt Leg installation Guide
SolarWorld Sunfix Ground Mount Installation manual Version: Tilt leg
America's Authority on Solar
May 2013
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Table of contents Introduction
5
General guidelines for installation personnel
6
Safety icons
7
General safety precautions and guidelines
8
Safety precautions and guidelines for SolarWorld solar modules
9
Unpacking and checking parts
10
Parts required for installaion
11
Tools required for Sunfix Ground Mount installation
13
Recycling packing materials
14
Checkpoints prior to installaion
15
Pre-installation procedure outline
16 General pre-installation guidelines
16
Example of completed Sunfix Ground Mount system
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Table row configuration
17
Table assembly order
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Installation procedure outline
18 Pre-assembly (optional)
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Pre-assembly list (optional)
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Step 1: Attach bottom bracket to CIDH or Earth Screw (Detail A)
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Step 2: Attach inner leg to bottom bracket assembly (Detail B)
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Step 3: Attach front outer leg to front inner leg assembly (Detail C)
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Step 4: Attach rear outer leg to rear inner assembly (Detail G)
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Step 5: Attach angled inner let to rear bottom bracket assembly (Detail F)
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Step 6: Attach angled outer let to angled inner leg assembly (Detail E)
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Step 7: Attach top bracket to front & angled leg assemblies (Detail D)
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Step 8: Attach top bracket to rear let assembly (Detail H)
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Step 9: Attach girder to top bracket assemblies (Section A-A)
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Step 10: Secure all materials
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Step 11: Create rope assembly (Detail J, Detail K)
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Step 12: Attach rope assemblies to front bracket assemblies (Detail J, Detail K)
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Step 13: Create rail clamp assembly (pre-assembly)
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Step 14: Attach splice plates to 3M beam (pre-assembly)
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Table of contents (continued)
4
Step 15: Attach lug and bolt set to hole on side of beams
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Step 16: Secure center beam
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STep 17: Secure outer beam
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Step 18: Table assembly order
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Step 19: Connect 3M beam/splice plate assembly to 7M & 8M long table assemblies
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Step 20: Attach lug and bolt set to hole on top of beam at row end
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Step 21: Create mid-clamp w/WEEB assembly for outer horizontal extrusion (pre-assembly)
46
Step22: Create mid-clamp assembly for inner horizontal extrusion (pre-assembly)
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Step 23: Create end clamp assemblies (pre-assembly)
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Step 24: Secure extrusions
49
Step 25: Attach Sunmodule Plus solar modules to table assembly
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Step 26: Secure all modules
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Introduction The SolarWorld Sunfix Ground Mount offers the premiere system for providing clean, environmentally-friendly solar power. This fully functional solar panel system provides much-needed clean, economical and environmentally-safe energy. Thank you for your contribution to the preservation and conservation of the earth. This installation manual provides step-by-step instructions, complete part specifications, safety warnings, and diagrams to successfully construct the Tilt Leg Version of the SolarWorld Sunfix Ground Mount with Sunmodule Plus Solar Modules.
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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General guidelines for installation personnel Please read this manual carefully before installing the system and carry out the installation procedures correctly. This manual does not list all precautions needed for safe work. Be sure to follow OSHA guidelines. This manual provides guidelines for installation, but it does not guarantee the quality of installation work. Please complete all work in a responsible and professional manner. Electrical work should be performed by a qualified electrician; this manual is for installation purposes only.
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Safety icons Various safety icons appear in this installation manual and on the products it describes. These icons are categorized, according to the consequences of ignoring the icons and handling the products inappropriately.
* * * D A N G E R O F D E AT H F R O M E L E C T R I C S H O C K ! * * * Sunmodule Plus Solar Modules generate electricity as soon as they are exposed to light. The voltage of a single module is less than 50 VDC. When several modules are connected in series, the summed voltage and current can be dangerously high. When the modules are connected in parallel the currents are summed together. Although touch protection is provided in the form of the fully insulated plug contacts, the following points must be observed when handling the Sunmodule Plus Solar Modules to avoid the risk of fire, arcing and fatal electric shock. _
The installation of the higher voltage systems should be done by qualified, licensed professionals.
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Do not insert electrically conducting parts into the plugs or sockets.
_
Do not wear metallic jewelry while performing mechanical or electrical installation.
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Do not fit Sunmodule Plus Solar Modules and wiring with wet plugs and sockets.
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Tools and working conditions must be dry.
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Exercise extreme caution when carrying out work on wiring and use the appropriate safety equipment (insulated tools, insulated gloves, etc.).
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Do not use damaged modules! Do not dismantle modules. Do not remove any part or label fitted by the manufacturer! Do not treat the rear of the laminate with paint, adhesives or mark it using sharp objects.
* * * D A N G E R O F D E AT H F R O M E L E C T R I C S H O C K ! * * * The inverter can produce dangerous, high voltages, even when not connected: _
Exercise extreme caution when working on wiring and the Inverter.
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After switching off the Inverter, it is essential to wait for the time interval specified by the manufacturer before beginning any further work. This allows the high voltage components time to discharge.
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Be sure carefully to follow the Inverter manufacturer’s Installation Instructions.
* * * D A N G E R O F D E AT H F R O M A R C I N G ! * * *
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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General safety precautions and guidelines The Tilt Leg Version of the SolarWorld Sunfix Ground Mount has been load-tested and verified by professional engineers. Testing information can be provided upon request. Always follow OSHA guidelines to prevent accidents; safety regulations must be observed. Always take the following precautions to prevent accidents and injury. Take the following precautions before beginning work: _
Plan the job and visit the site before starting work.
_
On site, do not work alone. Always work with at least one other person. When lifting over 50 lbs is required, work in teams of three. Each Sunmodule Plus Solar Module weighs approximately 50 lbs. Each extrusion weighs approximately 40 lbs to 50 lbs. It is highly recommended that you work in task crews with a minimum of three (3) trained installers for optimum safety and efficiency. See weights and measure specifications.
_
Inspect tools before using them.
Do not work under dangerous conditions: _
When it is raining, or there is a strong probability that it will start raining.
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When high wind conditions exist, or are expected, or when a high wind warning has been issued.
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When it is snowing, or when there is snow underfoot.
Wear appropriate work clothes and protective equipment:
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_
Work clothes for both the upper and lower body should fit well and allow you to move freely.
_
Always wear protective equipment, hard hat, work gloves, steel toe boots, eye protection, etc.
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Safety precautions and guidelines for SolarWorld solar modules _
Do not cut, drill into or modify SolarWorld Sunmodule Plus Solar Modules.
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Never step or sit on the glass surface of a SolarWorld Sunmodule Plus Solar Modules.
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Only use the supplied or specified parts to attach the SolarWorld Sunmodule Plus Solar Modules and tables.
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Only use the tools specified.
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Do not install near flammable liquids or gases.
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Do not drop or allow objects to fall onto modules.
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Do not use damaged modules.
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Keep the back sides of SolarWorld Sunmodule Plus Solar Modules free of foreign objects.
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Do not use chemicals on SolarWorld Sunmodule Plus Solar Modules when cleaning.
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Do not wear metallic jewelry, which may cause electrical shock.
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Do not expose SolarWorld Sunmodule Plus Solar Modules to concentrated sunlight from mirrors, lenses or similar means.
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Install SolarWorld Sunmodule Plus Solar Modules and systems according to applicable codes.
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SolarWorld Sunmodule Plus Solar Modules should be installed and maintained by qualified personnel. Keep unauthorized personnel away.
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Do not short-circuit SolarWorld Sunmodule Plus Solar Modules output cables.
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SolarWorld Sunmodule Plus Solar Modules generate electricity when exposed to sunlight.
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Unpacking and checking parts The utmost care is required when handling the modules. Take care when unpacking, transporting, and storing them. Leave modules in packaging until they are to be installed. Carry Sunmodule Plus Solar Modules with both hands. _
Do not use the connection socket as a handle.
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Do not stand modules on hard or rough ground.
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Do not stand modules on their corners.
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Ensure modules do not bow.
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Do not place modules on top of each other, except as originally packaged from SolarWorld.
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Do not subject to load, do not stand on them, do not drop.
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Do not mark or work on them with sharp objects.
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Keep all electrical contacts clean and dry.
In order to keep a record of your system, we recommend that you make a note of the serial numbers. If necessary to store the modules temporarily, a dry, ventilated room should be used.
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Parts required for installation Confirm count of all parts listed below prior to beginning installation. The parts list contains both anodized and non-anodized part descriptions and item numbers. SWCA Part Description
SWCA Part No.
BOTTOM BRACKET 240 mm MIL AL
EC0241
BOTTOM BRACKET 240 mm CLR ANO
EC0895
TOP BRACKET X BRACE MIL AL
EC1005
TOP BRACKET X BRACE CLR ANO
EC1006
U-FOOT PLATE 3/4" BLT MIL AL
EC0586
BOLT HXHD M12X100 DIN 931 A2
SA5227
WASHER FLAT M13 3X37 mm A2, DIN 9021
SA5228
NUT HEX M12 SERR FLANGE A2
SA5229
CLAMP 8 mm DIA ROPE SST
SA5124
THIMBLE 8 mm DIA A4
SA5125
WIRE ROPE 8 mm DIA SST
SA5126
TURNBUCKLE 10 mm A4
SA5127
SHACKLE ROUND M8 A4
SA5128
RING BOLT M10 DIN 580 A2
SK5037
CABLE CLIP ADJUSTABLE-CTR BEAM
EC0531
CABLE TIE 7" UV RES BLK 100PK
EC0399
SCREW PHP#10X3/4 TEK S/S 100PK
EC0400
MOUNT CBL TIE #10SCR 100PK BLK
EC0656
WASHER MOD GND WEEB DPF SST
EC0534
BUR WEEB PMC BOND WASH SST
EC0661
OUTER BEAM 6TBL 3072 mm MIL AL
EC0221
OUTER BEAM 10TBL 5092 mm MIL AL
EC0222
OUTER BEAM 12TBL 6102 mm MIL AL
EC0223
OUTER BEAM 14TBL 7112 mm MIL AL
EC0224
OUTER BEAM 16TBL 8122 mm MIL AL
EC0225
OUTER BEAM 6TBL 3072 mm CLR ANO
EC0705
OUTER BEAM 10TBL 5092 mm CLR ANO
EC0706
OUTER BEAM 12TBL 6102 mm CLR ANO
EC0707
OUTER BEAM 14TBL 7112 mm CLR ANO
EC0708
OUTER BEAM 16TBL 8122 mm CLR ANO
EC0709
GIRDER 2757 mm MIL AL
EC0226
GIRDER 2757 mm CLR ANO
EC0710
GIRDER HD 2757 mm MIL AL
EC0535
GIRDER HD 2757 mm CLR ANO
EC0922
CENTER BEAM 6TBL 3072 mm MIL AL
EC0675
CENTER BEAM10TBL 5092 mm MIL AL
EC0676
Notes
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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CENTER BEAM12TBL 6102 mm MIL AL
EC0677
CENTER BEAM14TBL 7112 mm MIL AL
EC0678
CENTER BEAM16TBL 8122 mm MIL AL
EC0679
CENTER BEAM6TBL 3072 mm CLR ANO
EC0684
CENTER BEAM10TBL 5092 mm CLR ANO
EC0685
CENTER BEAM12TBL 6102 mm CLR ANO
EC0686
CENTER BEAM14TBL 7112 mm CLR ANO
EC0687
CENTER BEAM16TBL 8122 mm CLR ANO
EC0688
BEAM CLAMP M10 BOLT MIL AL
EC0242
SPACER END CLAMP 30.4 mm MIL AL
EC0263
SPLICE PLATE 300 mm M10 MIL AL
EC0244
WASHER MOD CLAMP M8 4X36 mm A2
SA5079
BOLT HMHD M8X53 W/NOTCH A2
SH0002
NUT HEX M8 SERR FLANGE A2
EC0496
BOLT HMHD M10X30 W/NOTCH A2
SH5004
NUT HEX M10 SERR FLANGE A2
SK5017
NUT BREAK AWAY M8X13 mm A2
SK5068
OUTER LEG 560 mm MIL AL
EC0233
OUTER LEG 880 mm MIL AL
EC0234
OUTER LEG 1260 mm MIL AL
EC0235
OUTER LEG 1560 mm MIL AL
EC0236
OUTER LEG 1860 mm MIL AL
EC0237
INNER LEG 320 mm MIL AL
EC0238
INNER LEG 720 mm MIL AL
EC0239
OUTER LEG 320 mm CLR ANO
EC0880
OUTER LEG 560 mm CLR ANO
EC0881
OUTER LEG 880 mm CLR ANO
EC0882
OUTER LEG 1260 mm CLR ANO
EC0883
OUTER LEG 1560 mm CLR ANO
EC0884
OUTER LEG 1860 mm CLR ANO
EC0885
INNER LEG 320 mm CLR ANO
EC0886
INNER LEG 720 mm CLR ANO
EC0887
OPTIONAL
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Tools required for Sunfix Ground Mount installation Foundation type: Cast-in-drilled-hole (CIDH) or Earth Screws
1. ¾ Imperial Wrench (combination wrench 1-1/8”)
2. Ratcheting Wrench / Deep socket set with a 1-1/8” head size. 3. Impact Gun 4. Metric wrench / socket set with the following head sizes: 13 mm (for M8 T-Bolt), 15 mm (for M10 T-Bolt) 5. Torque wrench with setting range 10 ft-lb to 45 ft-lb 6. Measuring Tape in Millimeters (10 m)
7. 100 Foot Marking String for alignment
8. Anti-Seize Compound 9. 4 Foot Step Ladder 10. Torque Tools: 3/8” Drive for M8 and M10 fasteners 11. Torque Tools: ½” Drive for ¾” fasteners Optional tools for ground mount installation
1. Electric Torque Gun (Used at slow to medium speed only; NEVER high speed)
2. Laser for Alignment
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Recycling packing materials SolarWorld is committed to reduce the effect on the environment from packaging materials used in the manufacturing of photovoltaic arrays. Efforts have been made to reduce the amount of packaging material. SolarWorld only uses recyclable materials and/or arranges for its reuse. The following table describes the proper way to dispose of the different types of packaging materials which will be delivered to the job site: Category
Item
Where Used
Instructions
Contact
Cardboard
Boxes
Small extrusion pieces
Will be recycled by extrusion manufacturer.
None
Hardware
Recycle
None
Drums
Small extrusion pieces
Will be reused by extrusion manufacturer.
Contact SolarWorld for instructions.
Sheet
Outside extrusion bundles
Will be recycled by extrusion manufacturer.
None
Spacers
Inside extrusion bundles
Will be recycled by extrusion manufacturer.
None
Module cardboard
Module pallets
Will be reused by SolarWorld
Contact SolarWorld for instructions.
Paper
UL Documentation
Between each Sunmodule Plus Solar Module
Recycle
Have recycle container on site
Wood
Battens
Around extrusion bundles
Will be recycled by extrusion manufacturer.
Contact SolarWorld for instructions.
Module pallets
Modules
Will be recycled by SolarWorld
Contact SolarWorld for instructions.
Other pallets
Other products
Recycle
None
Wood Spools
Wire and cable
Will be collected by wire supplier
Contact SolarWorld for instructions.
Plastic Straps
Around extrusion bundles, around module bundles, around other pallets.
Recycle
None
Stretch wrap
Module pallets
Dispose
None
Module Installation Instructions
Modules
Will be reused by SolarWorld
None
Dispose
None
Other
Other (foam peanuts, Other black plastic corner protectors, bubble wrap, etc.)
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Checkpoints prior to installation _
Verify inventory of all materials and tools for installation
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Ensure that all T-Bolts have been pre-coated with an anti-seize compound and that T-Bolts are free from debris prior to assembly. (Optional: Pre-coat T-Bolts with an anti-seize compound to avoid galling. Store in a storage bag to protect from debris)
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Check power tools and hand tools
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Prior to mounting the SolarWorld Sunmodule Plus Solar Modules, make sure that the electrical junction box is faced toward the Center Beam. The top and bottom solar panels junction box will adjoin in the center. (Note: Junction box is located underneath SolarWorld Logo)
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When mounting SolarWorld Sunmodule Plus Solar Modules on the Extrusions, make sure the cables are secure, never allow an output cable to become caught between the Extrusion and a module frame. Short circuits and fire can result.
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Do not remove tape securing the cables until after installation is complete.
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Prior to mounting Sunmodule Plus Solar Modules, remove and recycle the black plastic protection corners and white foam spacers. (Refer to the Recycling Packing Materials)
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Pre-installation procedure outline General pre-installation guidelines This manual provides installation instructions for installing (1) Tilt Leg Version of the SolarWorld Sunfix Ground Mount and Sunmodule Plus Solar Module Panels for (1) Table at a time. Certain installation parts have multiple specifications, depending on procedure or whether the part is anodized or non-anodized. See table references for details.
Example of completed Sunfix Ground Mount system The following picture shows the completed installation of the Tilt Leg Version Sunfix Ground Mount system:
Pre-installation of cast-in-drilled-hole (CIDH) or Earth screw foundation and table lengths overview
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
The Installation Procedure Outline and following Steps provide instructions for how to complete a Table of any length. The part specifications used are for installing a 5M Long Table (10 Modules), 6M Long Table (12 Modules), 7M Long Table (14 Modules), 8M Long Table (16 Modules), and a connecting 3M Long Table (6 Modules). Each series of arrays are referred to as “Tables.” There are five (5) table lengths that will be utilized in the design and construction of this solar panel installation project:
1. 3M Table: 6 Solar Modules = 3 Sunmodule Plus Solar Modules x 2 Rows
2. 5M Table: 10 Solar Modules = 5 Sunmodule Plus Solar Modules x 2 Rows 3. 6M Table: 12 Solar Modules = 6 Sunmodule Plus Solar Modules x 2 Rows 4. 7M Table: 14 Solar Modules = 7 Sunmodule Plus Solar Modules x 2 Rows 5. 8M Table: 16 Solar Modules = 8 Sunmodule Plus Solar Modules x 2 Rows
Table row configuration Three (3) Table Row Configurations are shown below as examples, but many more configurations exist:
1. 46-Panel Table Configuration: 8M-3M-7M-5M
2. 92-Panel Table Configuration: 7M-3M-7M-3M-7M-3M-7M-3M-7M NOTE: The 92-Panel Table Configuration omits 2 Modules in portrait. 3. 138 Module Table Configuration: 8M-3M-7M-3M-7M-3M-7M-3M-7M-3M-7M-3M-8M NOTE: All Table Configuration specifications are described in order from West to East: Complete tables in consecutive order from one end of the row to the other.
Table assembly order
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Installation procedure outline Pre-assembly (optional) Step 1: Attach bottom bracket leg to CIDH (Detail A) or Earth Screw Step 2: Attach inner leg to bottom bracket assembly (Detail B) Step 3: Attach front outer leg to front inner leg assembly (Detail C) Setp 4: Attach rear outer leg to rear inner leg assembly (Detail G) Step 5: Attach angled inner let to rear bottom bracket assembly (Detail F) Step 6: Attach angled outer leg to angled inner leg assembly (Detail E) Step 7: Attach top bracket to front & angled leg assemblies (Detail D) Step 8: Attach top bracket to rear leg assembly (Detail H) Step 9: Attach girder to top bracket assemblies (Section A-A) Step 10: Secure all materials Step 11: Create rope assembly (Detail J, Detail K) Step 12: Attach rope assemblies to front bracket assemblies (Detail J, Detail K) Step 13: Create rail clamp assembly (optional pre-assembly) Step 14: Attach splice plates to 3M outer and center beam (optional pre-assembly) Step 15: Attach lug and bolt set to hole on side of beams Step 16: Secure center beams Step 17: Secure outer beams Step 18: Table assembly order Step 19: Connect 3M center beam/splice plate assembly and outer beam/splice plate assembly to 5M, 6M, 7M, and 8M long table assemblies Step 20: Create mid-clamp w/WEEB assembly for outer beam (optional pre-assembly) Step 21: Create mid-clamp assembly for center beam (optional pre-assembly) Step 22: Create end clamp assemblies (optional pre-assembly) Step 23: Secure all beams Step 24: Attach Sunmodule Plus solar modules to table assembly Step 25: Secure all modules and materials
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Pre-assembly list (optional) Pre-assemblies are subassemblies, which can be assembled on a bench prior to installation in the field. 1. Rail Clamp Assembly A. (1) T-Bolt M10X30 mm, SH5004 B. (1) Rail Clamp 70 mm, EC0242 C. (1) Flange Nut, M10 A2, SK5017 2. Mid-Clamp Assembly w/WEEB for Outer Horizontal Extrusion A. (1) Module Flat Washer (Ø36 mm X 4 mm Thick), SA5079 B. (1) Module T-Bolt (M8X53 mm), SH0002 C. (1) M8 Serrated Flange Hex Nut, EC0496 D. (1) WEEB-DPF, EC0534 3. Mid-Clamp Assembly for Center Beam A. (1) Module Flat Washer (Ø36 mm X 4 mm Thick), SA5079 B. (1) Module T-Bolt (M8X53 mm), SH0002 C. (1) M8 Serrated Flange Hex Nut, EC0496 4. End-Clamp Module w/WEEB Assembly A. (1) M8 Serrated Flange Hex Nut, EC0496 B. (1) End Clamp, EC0263 C. (1) Module Flat Washer (Ø36 mm X 4 mm Thick), SA5079 D. (1) Module T-Bolt (M8X53 mm), SH0002 E. (1) WEEB-PMC, EC0661 5. Splice Plate to 3M Outer Beam or Center Beam A. (1) 3M Outer Beam (3072 mm), EC0221/EC0705 OR (1) 3M Center Beam (3072 mm), EC0675/EC0684 B. (2) Splice Plate, 300 mm, EC0244 C. (4) T-Bolt, M10X30 mm, SH5004 D. (4) Flange Nut, M10 A2, SK5017 6. Top Bracket to Girder A. (2) Top Bracket, EC1005/EC1006 B. (4) T-Bolt M10X30 mm, SH5004 C. (4) Flange Nut, M10 A2, SK5017 D. (1) Girder (2757 mm), EC0226/EC0710 OR Girder HD (2757 mm), EC0535/EC0922
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Step 1: Attach bottom bracket to CIDH or Earth Screw (Detail A) Materials Required for Step 1 (4) Cast In Drilled Hole, (CIDH) or Earth Screw (Supplied by installer) (4) Bottom Bracket, EC0241/ECO895 (4) U-Foot Plate for ¾” Bolt, EC0586 (4) ø3/4” Anchor Bolt, hot dip galvanized (HDG), (Supplied by installer) (4) ø3/4” Flat Washer, HDG, (Supplied by installer) (4) ø3/4” Split Washer, HDG (Supplied by installer) (4) ø3/4” Nut, HDG (Supplied by installer)
1.1 Place (1) Anchor Bolt into CIDH hole or drive (1) Earth Screw into ground. (Refer to User design specification)
1.2 Align (1) Bottom Bracket rectangular hole on top of (1) Anchor Bolt or (1) Earth Screw. QUALITY CHECK: The length of the Bottom Bracket should be secured perpendicular to the length of the table, with the vertically parallel bolt holes facing towards the rear of the table, and the diagonally angled bolt holes facing towards the front of the table.
1.3 Place (1) U-Foot Plate on top of (1) Anchor Bolt or (1) Earth Screw.
1.4 Place (1) Flat Washer on top of (1) U-Foot Plate.
1.5 Place (1) Split Washer on top of (1) Flat Washer.
1.6 Place (1) Nut on top of (1) Split Washer.
NOTE: This creates (1) Bottom Bracket Assembly.
1.7 Repeat Steps 1.1 to 1.6 three (3) times.
OBJECTIVE: Attach (4) Bottom Brackets to (4) CIDH’s or (4) Earth Screws.
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Step 2: Attach inner leg to bottom bracket assembly (Detail B) Materials Required for Step 2 (4) Bottom Bracket Assembly (4) Inner Leg, 720 mm, EC0239/ECO887 (8) Bolt, M12x100 mm, SA5227 (8) Flat Washer, M13 3X37 mm, SA5228 (8) Flange Nut, M12 A2, SA5229 2.1 Place (1) Inner Leg inside (1) Bottom Bracket Assembly at a 90-degree vertical angle. 2.2
Align bottom (2) Inner Leg holes with (2) Bottom Bracket vertically parallel holes.
QUALITY CHECK: Use a Level to confirm angle consistency. 2.3 Insert (2) Flat Washers and (2) Bolts into (2) aligned holes. 2.4 Secure (2) Bolts with (2) Flange Nuts.
QUALITY CHECK: Use a Level to confirm angle consistency.
QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency. NOTE: This creates (1) Inner Leg Assembly. 2.5 Repeat Steps 2.1 to 2.4 three (3) times to attach (4) Inner Legs to (4) Bottom Bracket Leg Assemblies. OBJECTIVE: Attach (4) Inner Legs to (4) Bottom Bracket Assemblies.
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Step 3: Attach front outer leg to front inner leg assembly (Detail C) Materials Required for Step 3 (2) Front Inner Leg Assembly (2) Front Outer Leg, 560 mm, EC0233/ECO881 (4) Flat Washer, M13 3X37 mm, SA5228 (4) Bolt, M12x100 mm, SA5227 (4) Flange Nut, M12 A2, SA5229 3.1 Place (1) Front Outer Leg on top of (1) Inner Leg Assembly and lower until (2) Outer Leg holes are aligned with (2) Inner Leg holes. NOTE: Refer to “Chart 1” to determine part specification for Front Outer Leg. NOTE: Refer to “Chart 2” for angle and length measurements to determine hole alignment. 3.2 Insert (2) Flat Washers and (2) Bolts into (2) Outer Leg holes aligned with (2) Inner Leg holes. 3.3 Secure (2) Bolts with (2) Flange Nuts.
NOTE: This creates 1 Front Leg Assembly. 22
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
QUALITY CHECK: Use a Level to confirm angle consistency.
QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency.
QUALITY CHECK: See Torque table for final tightening specifications. 3.4 Repeat Steps 3.1 to 3.3 one (1) time.
OBJECTIVE: Attach (2) Front Outer Legs to (2) Inner Leg Assemblies.
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Step 4: Attach rear outer leg to rear inner assembly (Detail G) Materials Required for Step 4 (2) Rear Inner Leg Assembly (2) Rear Outer Leg, (See “Chart 1” for part specification) (4) Flat Washer, M13 3X37 mm, SA5228 (4) Bolt, M12x100 mm, SA5227 (4) Flange Nut, M12 A2, SA5229 4.1 Place (1) Rear Outer Leg on top of (1) Inner Leg Assembly and lower until (2) Outer Leg holes are aligned with (2) Inner Leg holes. NOTE: Refer to “Chart 1” to determine part specification for Rear Outer Leg. NOTE: Refer to “Chart 2” for angle and length measurements to determine hole alignment. 4.2 Insert (2) Flat Washers and (2) Bolts into (2) Outer Leg holes aligned with (2) Inner Leg holes. 4.3 Secure (2) Bolts with (2) Flange Nuts.
NOTE: This creates 1 Rear Leg Assembly.
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
QUALITY CHECK: Use a Level to confirm angle consistency.
QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency.
QUALITY CHECK: See Torque table for final tightening specifications. 4.4 Repeat Steps 4.1 to 4.3 one (1) time.
OBJECTIVE: Attach (2) Rear Outer Legs to (2) Inner Leg Assemblies. SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Step 5: Attach angled inner leg to rear bottom bracket assembly (Detail F) Materials Required for Step 5 (2) Rear Bottom Bracket Assembly (2) Inner Leg, 720 mm, EC0239/ECO887 (4) Flat Washer, M13 3X37 mm, SA5228 (4) Bolt, M12x100 mm, SA5227 (4) Flange Nut, M12 A2, SA5229 5.1 Place (1) Inner Leg inside (1) Rear Bottom Bracket.
5.2 Align bottom (2) Inner Leg holes with (2) Bottom Bracket diagonally angled holes. 5.3 Insert (2) Flat Washers and (2) Bolts into (2) aligned holes. 5.4 Secure (2) Bolts with (2) Flange Nuts.
NOTE: This creates 1 Angled Inner Leg Assembly. QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency. 5.5 Repeat Steps 5.1 to 5.4 one (1) time. OBJECTIVE: Attach (2) Inner Legs to (2) Rear Bottom Bracket Assemblies.
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Step 6: Attach angled outer leg to angled inner leg assembly (Detail E) Materials Required for Step 6 (2) Angled Inner Leg Assembly (2) Angled Outer Leg, (See “Chart 1” for part specification) (4) Flat Washer, 3x37 mm, SA5228 (4) Bolt, M12x100 mm, SA5227 (4) Flange Nut, M12 A2, SA5229 6.1 Place (1) Angled Outer Leg on top of (1) Angled Inner Leg Assembly and lower until (2) Outer Leg holes are aligned with (2) Inner Leg holes. NOTE: Refer to “Table 1” to determine part specification for Rear Outer Leg. NOTE: Refer to “Chart 2” for angle and length measurements to determine hole alignment. 6.2 Insert (2) Flat Washers and (2) Bolts into (2) Outer Leg holes aligned with (2) Inner Leg holes. 6.3 Secure (2) Bolts with (2) Flange Nuts.
NOTE: This creates 1 Angled Leg Assembly. QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency.
QUALITY CHECK: See Torque table for final tightening specifications. 6.4 Repeat Steps 6.1 to 6.3 one (1) time
OBJECTIVE: Attach (2) Angled Outer Legs to (2) Angled Inner Leg Assemblies. SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Step 7: Attach top bracket to front & angled leg assemblies (Detail D) Materials Required for Step 7 (2) Top Bracket, EC1005/EC1006 (2) Front Leg Assembly (2) Angled Leg Assembly (8) Flat Washer, M13 3X37 mm, SA5228 (8) Bolt, M12x100 mm, SA5227 (8) Flange Nut, M12 A2, SA5229 7.1 Place (1) Top Bracket on top of (1) Front Leg Assembly, and align (2) Top Bracket holes with (2) Front Leg holes.
7.2 Insert (2) Flat Washers and (2) Bolts into (2) Top Bracket holes aligned with (2) Front Leg holes.
7.3 Secure (2) Bolts with (2) Flange Nuts by finger-tightening ONLY.
NOTE: Adjust by finger-tightening to allow adjustments for securing Girder in Step 9. QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency. 7.4 Place other end of Top Bracket on top of (1) Angled Leg Assembly, and align (2) Top Bracket holes with (2) Angled Leg holes.
7.5 Insert (2) Flat Washers and (2) Bolts into (2) Top Bracket holes aligned with (2) Angled Leg holes.
7.6 Secure (2) Bolts with (2) Flange Nuts by finger-tightening ONLY.
NOTE: Adjust by finger-tightening to allow adjustments for securing Girder in Step 9.
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QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency.
7.7 Confirm 90 degree vertical angle of Front Leg Assembly with Level.
7.8 Torque (2) Bolts on (1) Front Bottom Bracket. QUALITY CHECK: See Torque table for final tightening specifications.
NOTE: Do NOT torque Top Bracket Bolts. This creates 1 Front Top Bracket Assembly.
7.9 Repeat Steps 7.1 to 7.8 (1) time.
OBJECTIVE: Attach (2) Top Brackets to (2) Front Leg Assemblies and (2) Angled Leg Assemblies. SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Step 8: Attach top bracket to rear leg assembly (Detail H) Materials Required for Step 8 (2) Top Bracket, EC1005/EC1006 (2) Rear Leg Assembly (4) Flat Washer, M13 3X37 mm, SA5228 (4) Bolt, M12x100 mm, SA5227 (4) Flange Nut, M12 A2, SA5229 8.1 Place (1) Top Bracket on top of (1) Rear Leg Assembly, and align (2) Top Bracket holes with (2) Rear Leg holes. QUALITY CHECK: The extra holes on the Top Bracket should face away from the Table. 8.2 Insert (2) Flat Washers and (2) Bolts into the (2) Top Bracket holes aligned with (2) Rear Leg holes. 8.3 Secure (2) Bolts with (2) Flange Nuts by finger-tightening ONLY. QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency. NOTE: Adjust by finger-tightening to allow adjustments for securing Girder in Step 9. 8.4 Confirm 90 degree vertical angle of Rear Leg Assembly with Level. 8.5 Torque (2) Bolts on (1) Rear Bottom Bracket. QUALITY CHECK: See Torque table for final tightening specifications.
NOTE: Do NOT torque Top Bracket Bolts. NOTE: This creates 1 Rear Top Bracket Assembly. 8.6 Repeat Steps 8.1 to 8.5 one (1) time. OBJECTIVE: Attach (2) Top Brackets to (2) Rear Leg Assemblies. 30
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Step 9: Attach girder to top bracket assemblies (Section A-A) Materials Required for Step 9 (2) Girder HD, 2757 mm, EC0535/EC0922 or Girder, 2757 mm, EC0226/EC0710 (8) T-Bolt, M10x30 mm, SH5004 (8) Hex Nut, M10, SK5017 (2) Front Top Bracket Assembly (2) Rear Top Bracket Assembly 9.1 Place (1) Girder on top of (1) Front Top Bracket Assembly and (1) Rear Top Bracket Assembly. NOTE: Refer to “Chart 2” to determine overhang measurements. QUALITY CHECK: Use measuring tape to verify distances. 9.2 Place (2) T-Bolt heads into (2) Front Top Bracket holes with T-Bolt heads facing towards Girder, and rotate (2) Bolts 90 degrees. QUALITY CHECK: Indentation line on bottom of T-Bolt body should be perpendicular to Girder. 9.3 Secure (2) T-Bolts by screwing (2) Hex Nuts onto bottom of (1) Front Top Bracket. 9.4 Rotate (1) Rear Top Bracket parallel to (1) Girder. 9.5 Place (2) T-Bolt heads into (2) Rear Top Bracket holes with T-Bolt heads facing towards Girder, and rotate (2) T-Bolts 90 degrees. QUALITY CHECK: Indentation line on bottom of T-Bolt body should be perpendicular to Girder. 9.6 Secure (2) T-Bolts by screwing (2) Hex Nuts onto bottom of (1) Rear Top Bracket.
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9.7 Reconfirm 90 degree vertical angle of Front and Rear Leg Assembly with Level. 9.8 Repeat Steps 9.1 to 9.8 one (1) time. QUALITY CHECK: Refer to “Chart 3” to confirm Girder overhang measurements. 9.9 Torque Top Bracket T-Bolts. QUALITY CHECK: See Torque table for final tightening specifications. OBJECTIVE: Attach (2) Girders to (4) Top Bracket Assemblies.
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Step 10: Secure all materials 10.1 Once all table construction has been completed, torque all materials. Torque Table Torque Requirements
Nm
ft-lb
Flange Nut Serrated, M8, EC0496
20
15
Flange Nut, M10, SK5017
30
22
Hex Nut Serrated, M12, SA5229
28
21
QUALITY CHECK: Confirm torque specifications for previously torqued materials.
OBJECTIVE: To ensure safety and functionality of Ground Mount.
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Step 11: Create rope assembly (Detail J, Detail K) Materials Required for Step 11 (8) Ring Bolt, M10, SK5037 (12) Shackle Body, M8, SA5128 (12) Shackle Pin, M8, SA5128 M8, SA5128 (4) Turnbuckle, 10 mm, SA5127 (8) Thimble, 8 mm DIA ROPE SST, SA5125 (32) Clamp Assembly, 8 mm DIA ROPE SST, SA5124 (4) M8 Wire Rope, 8 mm DIA SST, SA5126 NOTE: U-Bolt, Saddle and Hex Nut are referred to as Clamp Assembly. 11.1 Insert end of (1) Wire Rope into (4) Clamp Assemblies. Fold end of wire Rope with approximately 200 mm of overlap, and place (1) Thimble underneath Rope bend. NOTE: Rope overhang of 200 mm should begin after Thimble. 11.2 Position (1) Clamp Assembly adjacent to (1) Thimble, and secure Clamp Assembly with (2) Hex Nuts. NOTE: Saddle should be secured on long side of rope. 11.3 Position remaining (3) Clamp Assemblies approximately 50 mm away each from (1) secured Clamp Assembly, and secure with (6) Hex Nuts. QUALITY CHECK: Remaining Rope overhang should be approximately 50 mm. 11.4 Cut Rope overhang at approximately 200 mm from last Clamp Assembly. 11.5 Insert (1) Shackle Body into (1) Thimble. 11.6 Insert (1) Turnbuckle end into (1) Shackle Body, and secure by inserting (1) Shackle Pin into (1) Shackle Body. 11.7 Insert another (1) Shackle Body into (1) Ring Bolt. 11.8 Insert other end of (1) Turnbuckle into (1) Shackle, and secure by inserting (1) Shackle Pin into (1) Shackle Body.
NOTE: This creates 1 Turnbuckle Assembly. 11.9 Insert end of (1) Wire Rope into (4) Clamp Assemblies. Fold end of Rope with approximately 200 mm of overlap, and place Thimble underneath Rope bend. NOTE: Rope overhang of 200 mm should begin after Thimble. 34
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Step 11: Create rope assembly continued (Detail J, Detail K) 11.10 Position (1) Clamp Assembly adjacent to Thimble, and secure with (2) Hex Nuts. 11.11 Position remaining (3) Clamp Assemblies approximately 50 mm away each from (1) secured Clamp Assembly, and secure with (6) Hex Nuts. 11.12 Cut Rope overhang at approximately 200 mm from last Clamp Assembly. 11.13 Insert (1) Shackle Body into (1) Ring Bolt. 11.14 Insert (1) Shackle Body with Ring Bolt into (1) Thimble, and secure by inserting (1) Shackle Pin into (1) Shackle Body.
NOTE: This creates 1 Rope Assembly. 11.15 Repeat Steps 11.1 to 11.14 three (3) times. OBJECTIVE: Create (4) Rope Assemblies.
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Step 12: Attach rope assemblies to front bracket assemblies (Detail J, Detail K) Materials Required for Step 12 (4) Rope Assemblies (8) Hex Nut, M10 Serrated Flange A2, SK5017 (2) Front Top Bracket Assembly (2) Front Bottom Bracket Assembly 12.1 Insert (1) Ring Bolt on end of (1) Turnbuckle Assembly into center hole of (1) Front Top Bracket. 12.2 Secure (1) Ring Bolt with (1) Hex Nut. 12.3 Insert (1) Ring Bolt on other end of (1) Rope Assembly into center hole of (1) Front Bottom Bracket on adjacent front leg of the Table. 12.4 Secure (1) Ring Bolt with (1) Hex Nut.
QUALITY CHECK: The (1) Rope Assembly should form a diagonal angle from the top front of the Table to the bottom front of the Table. 12.5 Insert (1) Ring Bolt on end of (1) Turnbuckle Assembly into center hole of other (1) Front Top Bracket. 12.6 Secure (1) Ring Bolt with (1) Hex Nut. 12.7 Insert (1) Ring Bolt on other end of (1) Rope Assembly into center hole of other (1) Front Bottom Bracket on adjacent front leg of the Table. 12.8 Secure (1) Ring Bolt with (1) Hex Nut.
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QUALITY CHECK: The (2) Rope Assemblies should form crisscrossing, diagonal angles from the top fronts of the Table to the bottom fronts of the Table. 12.9 Wait until all Extrusions are secured in Step 17 to adjust tightness of (2) Turnbuckle Assemblies until no longer slack.
NOTE: Turnbuckle automatically loosens upon reaching maximum tightness. OBJECTIVE: Attach (2) Rope Assemblies to (4) Front Bracket Assemblies. SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Step 13: Create rail clamp assembly (pre-assembly) Materials Required for Step 13 (12) Flange Nut, M10 A2, SK5017 (12) Rail Clamp, 70 mm, EC0242 (12) T-Bolt, M10X30 mm, SH5004
13.1 Place (1) T-Bolt inside (1) Rail Clamp with grooves pointing towards T-Bolt. 13.2 Screw (1) Flange Nut loosely on top of Rail Clamp. NOTE: This creates (1) Rail Clamp Assembly. 13.3 Repeat Steps 13.1-13.2 eleven (11) times. Materials Required for 5M and 6M Long Table: (6) Flange Nut, M10 A2, SK5017 (6) Rail Clamp, 70 mm, EC0242 (6) T-Bolt, M10X30 mm, SH5004 13.4 Repeat Steps 13.1-13.2 six (6) times. OBJECTIVE: Create Rail Clamp Assemblies to secure Beams in Steps 16-17.
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Step 14: Attach splice plates to 3M beam (pre-assembly) Materials Required for 7M, and 8M Long Table: (2) Outer Beam, 3072 mm, EC0221/EC0705 (1) Center Beam, 3072 mm, EC0675/EC0684 (6) Splice Plate, 300 mm, EC0244 (12) T-Bolt, M10X30 mm, SH5004 (12) Flange Nut, M10 A2, SK5017
14.1 Slide (1) Splice Plate with angles facing up halfway under the bottom of (1) Outer Beam. 14.2 Place (2) T-Bolts heads into (2) holes on (1) Splice Plate and rotate 90 degrees. 14.3 Secure (4) T-Bolts by screwing (4) Flange Nuts onto bottom of (1) Splice Plate. NOTE: This creates (1) 3M Beam/Splice Plate Assembly. 14.4 Repeat Steps 14.1 to 14.3 five (5) times. OBJECTIVE 1: Provide the foundation to connect the Beam for the 3M Long Table to 5M, 6M, 7M, and 8M Long Table. OBJECTIVE 2: To use as measuring stick for Beams in Steps 16-17.
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Step 15: Attach lug and bolt set to hole on side of beams Materials Required for 5M, 6M, 7M and 8M Long Table: (6) Lay-In Lug, EC1057 (6) Bolt Set (Serrated Washer, Washer, Bolt, & Nut), EC0149 15.1 Align (1) Lay-In Lug hole with (1) ¼” pre-drilled hole on the side of (1) Beam of each table. 15.2 Align (1) Washer with (1) Lay-In Lug top hole, and place (1) Bolt inside (1) Lay-In Lug top Hole. 15.3 Align (1) Serrated Washer under (1) Lay-In Lug bottom hole. 15.4 Secure (1) Bolt by screwing (1) Nut onto inside wall of (1) Beam. 15.5 Align (1) Lay-In Lug hole with (1) ¼” pre-drilled hole on the other side of same (1) Beam of each table. 15.6 Align (1) Washer with (1) Lay-In Lug top hole, and place (1) Bolt inside (1) Lay-In Lug top Hole. 15.7 Align (1) Serrated Washer under (1) Lay-In Lug bottom hole. 15.8 Secure (1) Bolt by screwing (1) Nut onto inside wall of (1) Beam. 15.9 Repeat Steps 15.1-15.8 for each of remaining (2) Beams per (1) Table. OBJECTIVE: Attach Lugs and Bolt Sets to pre-drilled holes on sides of 3 Beams per (1) Table.
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Step 16: Secure center beam Materials Required for 5M, 6M, 7M, and 8M Long Table: (1) Center Beam, (refer to "Chart 1") (4) Rail Clamp Assemblies
16.1 Place (1) Center Beam across the center of (2) Girders, with approximately 51.5” (1308 mm) from the edge of the Girders. Use a laser to align all Center Beams in each row. 16.2 Secure (1) Center Beam by attaching (1) Rail Clamp Assembly below and against the Center Beam on top of each Girder and finger-tighten. 16.3 Place (1) Rail Clamp Assembly above and against the Center Beam on top of each Girder and finger-tighten. QUALITY CHECK: The Center Beam should be centered on the Girders, approximately 51.5” (1308 mm) from the edge of the Vertical Girders. Use measuring tape to verify distance. QUALITY CHECK: For end tables only, the Center Beam should have a horizontal overhang extending approximately 37.5” (952.5 mm) past the Girders. Note: 8M tables will extend further toward the row end. Use measuring tape to verify distance.
QUALITY CHECK: Use a String Line or Laser to confirm angle consistency. OBJECTIVE: To secure the Center Beam exactly in the middle of the Girders with enough overhang to attach the 3M Horizontal Extrusions.
Step 17: Secure outer beam SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Materials Required for 5M, 6M, 7M, and 8M Long Table: (2) Outer Beam, (refer to "Chart 1") (8) Rail Clamp Assemblies
17.1 Place (2) Rail Clamp Assemblies on top of (2) Girders approximately ¼” from the bottom and secure by finger- tightening. 17.2 Place (1) Outer Beam above and against the (2) Rail Clamp Assemblies. 17.3 Place (2) Rail Clamp Assemblies on top of (2) Girders above and against (1) Outer Beam and secure by finger- tightening. 17.4 Repeat Steps 17.1-17.3 to secure the top Outer Beam by first attaching (2) Rail Clamp Assemblies approximately ¼” from the top of (2) Girders. NOTE: The completion of this step creates (1) Table Assembly (5M, 6M 7M, or 8M length). 17.5 Adjust tightness of (2) Turnbuckle Assemblies until no longer slack (See Step 12 for review). QUALITY CHECK: The Rail Clamp Assemblies for the Outer Beam should be at a ¼” distance from the bottom and top edges of the Girders. Use measuring tape to verify distance.
QUALITY CHECK: The Outer Beam should extend approximately 37.5’’ (952.5 mm) to the inside of the row. Note: 8M tables will extend further toward the row end. Use measuring tape to verify distance.
QUALITY CHECK: Use (1) 3M Beam /Splice Plate Assembly as a measuring stick to confirm that the 37.5” (952.5 mm) overhang distance for Beam on adjacent tables is sufficient to fit 3M Beams.
QUALITY CHECK: Use a String-line or Laser to confirm angle consistency. OBJECTIVE: To secure the Outer Beams.
Step 18: Table assembly order
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The following is an example of the table configurations, but there are many possible configuration options. 18.1 Start at one end of the row (7M Table or 8M Table only) and move to the other end. First install the 8M End Table, then the adjacent 7M Table, using the 3M Beam as a spacer. Next install the adjacent 7M Table and continue installing adjacent tables until the end of the row is reached. The last table installed is the 5M or 6M Table, if applicable. Please see the diagram below. QUALITY CHECK: Use 3M Beams with Splice Plates as spacers with 1/4" in between the ends of the beams.
QUALITY CHECK: Use a String line or Laser to confirm angle consistency.
QUALITY CHECK: Use 3M Beam as a spacer for 7M and 8M Tables
OBJECTIVE: Install all Table Assemblies prior to installation of 3M Table Leafs in Step 19 and Sunmodule Plus Solar Modules in Step 24.
Step 19: Connect 3M beam/splice plate assembly to 7M and 8M long table assemblies
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Note: Prior to beginning Step 19, all 7M and 8M Table Assemblies should be installed. Materials Required for 7M and 8M Long Table: (2) Table Assembly, (7M or 8M Long) (6) 3M Beam/Splice Plate Assembly
19.1 Place (1) 3M Beam/Splice Plate Assembly in between (2) Beams from (2) Table Assemblies, with the Splice Plates on the bottom. 19.2 Place (4) T-Bolts heads into (4) remaining holes on (2) Splice Plate Assemblies and rotate 90 degrees. 19.3 Secure (4) T-Bolts by screwing (4) Flange Nuts onto bottoms of (2) Splice Plate Assemblies. 19.4 Repeat Steps 19.1 to 19.3 three (3) times. NOTE: This creates (1) 3M Table Leaf. 19.5 Install all 3M Beam/Splice Plate Assemblies to all Table Assemblies prior to Step 24. NOTE: All 3M Table Leafs should be installed prior to placement of Sunmodule Plus Solar Modules in Step 24. OBJECTIVE: Connect 3M Beam/Splice Plate Assemblies to Table Assemblies to create (1) 3M Table Leaf.
Step 20: Attach lug and bolt set to hole on top of beam at row end 44
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Materials Required for 5M, 6M, 7M and 8M Long Table: (6) EC1057 Lay-In Lug (6) ECO149 Bolt Set (Serrated Washer, Washer, Bolt, & Nut) 20.1 At the end of the row, drill a ¼” hole approximately ½” away from the end of (1) Beam on the top surface. Please note that newer versions of the Beams have this hole prefabricated. 20.2 Align (1) Lay-In Lug hole with (1) ¼” pre-drilled hole at the end (1) Beam of table at end of row. 20.3 Align (1) Washer with (1) Lay-In Lug top hole, and place (1) Bolt inside (1) Lay-In Lug top Hole. 20.4 Align (1) Serrated Washer under (1) Lay-In Lug bottom hole. 20.5 Secure (1) Bolt by screwing (1) Nut onto inside wall of (1) Beam.
20.6 Repeat Steps 20.1-20.5 one (1) time for the other end of Table row. OBJECTIVE: Attach Lugs and Bolt Sets to pre-drilled holes on top of beams at row ends.
Step 21: Create mid-clamp w/WEEB assembly for outer horizontal extrusion (pre-assembly)
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Materials Required for 8M Long Table: (14) M8 Serrated Flange Hex Nut, EC0496 (14) Module Flat Washer, 36 mm X 4 mm, SA5079 (14) Module T-Bolt M8X53 mm, SH0002 (14) WEEB-DPF, EC0534
Materials Required for 7M Long Table: (12) M8 Serrated Flange Hex Nut, EC0496 (12) Module Flat Washer, 36 mm X 4 mm, SA5079 (12) Module T-Bolt M8X53 mm, SH0002 (12) WEEB-DPF, EC0534
Materials Required for 6M Long Table: (10) M8 Serrated Flange Hex Nut, EC0496 (10) Module Flat Washer, 36 mm X 4 mm, SA5079 (10) Module T-Bolt M8X53 mm, SH0002 (10) WEEB-DPF, EC0534
Materials Required for 5M Long Table: (8) M8 Serrated Flange Hex Nut, EC0496 (8) Module Flat Washer, 36 mm X 4 mm, SA5079 (8) Module T-Bolt M8X53 mm, SH0002 (8) WEEB-DPF, EC0534
Materials Required for 3M Leaf Table: (4) M8 Serrated Flange Hex Nut, EC0496 (4) Module Flat Washer, 36 mm X 4 mm, SA5079 (4) Module T-Bolt M8X53 mm, SH0002 (4) WEEB-DPF, EC0534 21.1 Place (1) Module T-Bolt inside (1) WEEB-DPF. Place (1) Module Flat Washer on top of (1) WEEB-DPF. 21.2 Screw (1) M8 Serrated Flange Hex Nut loosely on top of (1) Module Flat Washer. 21.3 Repeat Steps 21.1-21.2 the number of times listed in the material box, depending on table size to create (X) Rail Clamp Assemblies. For example, a 7M Long Table requires (12) Inner Module Assemblies. OBJECTIVE: Create Mid-Clamp w/WEEB Assemblies to secure Sunmodule Plus Solar Modules in Step 14.
Step 22: Create mid-clamp assembly for inner horizontal extrusion (pre-assembly) 46
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Materials Required for 8M Long Table: (16) M8 Serrated Flange Hex Nut, EC0496 (16) Module Flat Washer, 36 mm X 4 mm, SA5079 (16) Module T-Bolt M8X53 mm, SH0002
Materials Required for 7M Long Table: (14) M8 Serrated Flange Hex Nut, EC0496 (14) Module Flat Washer, 36 mm X 4 mm, SA5079 (14) Module T-Bolt M8X53 mm, SH0002
Materials Required for 6M Long Table: (12) M8 Serrated Flange Hex Nut, EC0496 (12) Module Flat Washer, 36 mm X 4 mm, SA5079 (12) Module T-Bolt M8X53 mm, SH0002
Materials Required for 5M Long Table: (10) M8 Serrated Flange Hex Nut, EC0496 (10) Module Flat Washer, 36 mm X 4 mm, SA5079 (10) Module T-Bolt M8X53 mm, SH0002
Materials Required for 3M Leaf Table: (6) M8 Serrated Flange Hex Nut, EC0496 (6) Module Flat Washer, 36 mm X 4 mm, SA5079 (6) Module T-Bolt M8X53 mm, SH0002 22.1 Place (1) Module T-Bolt inside (1) Module Flat Washer. 22.2 Screw (1) M8 Serrated Flange Hex Nut loosely on top of Flat Washer. 22.3 Repeat Steps 23.1-23.2 the number of times listed in the Materials box, depending on table size to create (X) Rail Clamp Assemblies. For example, a 7M Long Table requires (14) Inner Module Assemblies. OBJECTIVE: Create Mid-Clamp Assemblies to secure Sunmodule Plus Solar Modules in Step 25.
Step 23: Create end clamp assemblies (pre-assembly)
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Materials Required for all Tables: (4) Module T-Bolt M8X53 mm, SH0002 (4) Module Flat Washer, 36 mm X 4 mm Thick, SA5079 (4) End Clamp, EC0263 (4) M8 Serrated Flange Hex Nut, EC0496 (4) WEEB-PMC, EC0661 23.1 Place (1) Module T-Bolt inside (1) WEEB-PMC and (1) End Clamp, followed by (1) Module Flat Washer. 23.2 Screw (1) M8 Serrated Flange Hex Nut loosely on top of Flat Washer. This creates (1) End Clamp Assembly. 23.3 Repeat Steps 23.1-23.2 three (3) times to create (4) End Clamp Assemblies. OBJECTIVE: Create End Clamp Assemblies to secure Sunmodule Plus Solar Modules in Step 25.
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24.1 Once all table construction has been completed, secure all Extrusions on all Tables with final tightening. Follow Torque table for final tightening: Torque Table Torque Requirements
Nm
ft-lb
Flange Nut Serrated, M8, EC0496
20
15
Flange Nut, M10, SK5017
30
22
Hex Nut Serrated, M12, SA5229
28
21
OBJECTIVE: To ensure safety and functionality of Sunmodule Plus Solar Modules and Tables.
Step 25: Attach Sunmodule Plus solar modules to table assembly
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NOTE: Prior to beginning STEP 25, all 3M Table Leafs should be installed. Materials Required for 8M Long Table: (1) Table Assembly (8M Long) (16) Sunmodule Plus Solar Module, 31 mm (14) Mid-Clamp w/WEEB Assemblies (16) Mid-Clamp Assemblies (4) End Clamp w/WEEB Assemblies
Materials Required for 7M Long Table: (1) Table Assembly (7M Long) (14) Sunmodule Plus Solar Module, 31 mm (12) Mid-Clamp w/WEEB Assemblies (14) Mid-Clamp Assemblies (4) End Clamp w/WEEB Assemblies
Materials Required for 6M Long Table: (1) Table Assembly (6M Long) (12) Sunmodule Plus Solar Module, 31 mm (10) Mid-Clamp w/WEEB Assemblies (12) Mid-Clamp Assemblies (4) End Clamp w/WEEB Assemblies
Materials Required for 5M Long Table: (1) Table Assembly (5M Long) (10) Sunmodule Plus Solar Module, 31 mm (8) Mid-Clamp w/WEEB Assemblies (10) Mid-Clamp Assemblies (4) End Clamp w/WEEB Assemblies
Materials Required for 3M Long Table Leaf: (1) 3M Table Leaf (6) Sunmodule Plus Solar Module, 31 mm (4) Mid-Clamp w/WEEB Assemblies (6) Mid-Clamp Assemblies (4) End Clamp w/ WEEB Assemblies 25.1 Starting at the end of one table, place (1) Sunmodule Plus Solar Module in between the top Outer Beam and the Center Beam, approximately 2” from the ends. The Solar Module should rest against the groove of the Center Beam. Position module in the East/West direction so that the back of the End Clamp is flush with the end of the Outer Beam.
Step 25: Continued: Attach Sunmodule Plus solar modules to table assembly 50
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
QUALITY CHECK: The top Sunmodule Plus Solar Module should show the SolarWorld logo upside down at the bottom next to the Center Beam, with Junction Box resting on the Center Beam.
25.2 Secure (1) Sunmodule Plus Solar Module by placing (1) End Clamp Assembly at the end of the top Outer Beam. Place the Module T-Bolt upside down into the groove. Rotate the Module T-Bolt 90 degrees and finger-tighten the M8 Serrated Flange Hex Nut. QUALITY CHECK: To ensure that the End Clamp Assembly is secured, the line on the M8 Serrated Flange Hex Nut should be perpendicular to the Beam. Note: See photo for the positioning of end clamp which is flush with the beam. 25.3 Place a second Sunmodule Plus Solar Module in between the bottom Outer Beam and the Center Beam, leaving approximately 2” from the ends.
QUALITY CHECK: The bottom Sunmodule Plus Solar Module should show the SolarWorld logo at the top next to the Center Beam, with Junction Box resting on the Center Beam.
25.4 Secure the bottom Sunmodule Plus Solar Module by placing (1) End Clamp Assembly at the end of the bottom Outer Beam. Place the Module T-Bolt upside down into the groove. Rotate the Module T-Bolt 90 degrees and finger-tighten the M8 Serrated Flange Hex Nut.
Step 25 continued: Attach Sunmodule Plus solar modules to table assembly
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
51
25.5 Place (2) Mid-Clamp Assemblies on the Center Beam, in the middle of the 2nd cell outlined on the tops of the Sunmodule Plus Solar Module. Place the Module T-Bolt upside down into the groove. Rotate the Module TBolt 90 degrees and finger-tighten the M8 Serrated Flange Hex Nut.
QUALITY CHECK: To ensure that the Inner Module Assembly Clamp is secured, the line on the M8 Module T-Bolt should be perpendicular to the Beam.
25.6 Place (2) Mid-Clamp w/WEEB Assemblies on the Outer Beams, against the side of (2) Sunmodule Plus Solar Modules opposite the (2) End Clamp Assemblies. Place the (2) Module T-Bolts upside down into the groove and rotate the Module T-Bolts 90 degrees. Lift (2) Sunmodule Plus Solar Module slightly to fit (2) WEEBs underneath. NOTE: Do not finger-tighten (2) M8 Serrated Flange Hex Nuts until adjacent Sunmodule Plus Solar Modules have been secured. QUALITY CHECK: Use a 5/16” Spacer or spare Module T-Bolt to measure ¼” distance between additional Sunmodule Plus Solar Modules prior to installation. Secure the (2) M8 Serrated Flange Hex Nuts by finger-tightening. QUALITY CHECK: To ensure that the Mid-Clamp Assembly is secured, the line on the M8 Module T-Bolt should be perpendicular to the Beam. 25.7 Place a third Sunmodule Plus Solar Module in between the top Outer Beam and the Center Beam, with a 5/16” measured gap, using Spacer or spare Module T-Bolt, between the adjacent (1) Sunmodule Plus Solar Module. The Sunmodule Plus Solar Module should rest against the groove of the Center Beam.
Step 25 continued: Attach Sunmodule Plus solar modules to table assembly
52
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
QUALITY CHECK: The Module Flat Washer from the Mid-Clamp w/WEEB Assembly should rest atop the third Solar Panel.
25.8
Secure third Sunmodule Plus Solar Module by finger-tightening (1) M8 Serrated Flange Hex Nuts on the MidClamp w/WEEB Assembly.
25.9
Place a fourth Sunmodule Plus Solar Module in between the bottom Outer Beam and the Center Beam, with a ¼” measured gap between the adjacent (1) Sunmodule Plus Solar Module.
QUALITY CHECK: The bottom Sunmodule Plus Solar Module should show the SolarWorld logo at the top next to the Center Beam, with Junction Box resting on the Center Beam. 25.10 Secure the fourth Sunmodule Plus Solar Module by finger-tightening (1) M8 Serrated Flange Hex Nuts on the Mid-Clamp w/WEEB Assembly. 25.11 Place (2) Mid-Clamp Assemblies on the Center Beam, in the middle of the 2nd squares outlined on the tops of the Sunmodule Plus Solar Module. Place the Module T-Bolt upside down into the groove. Rotate the Module T-Bolt 90 degrees and finger-tighten the M8 Serrated Flange Hex Nut. QUALITY CHECK: To ensure that the Mid-Clamp Assembly is secured, the line on the M8 Serrated Flange Hex Nut should be perpendicular to the Beam. 25.12 Place (2) Mid-Clamp w/WEEB Assemblies on the Outer Beams, against the side of (2) Sunmodule Plus Solar Modules opposite the (2) End Clamp Assemblies. Place the (2) Module T-Bolts upside down into the groove and rotate the Module T-Bolts 90 degrees. Lift (2) Sunmodule Plus Solar Module slightly to fit (2) WEEBs underneath. 25.13 Repeat Steps 26.7-26.10 to secure the remaining inner Sunmodule Plus Solar Modules in the same portrait orientation. Secure the (2) Sunmodule Plus Solar Modules at the other end of the table with (2) End Clamp Assemblies, as explained in Step 25.2. QUALITY CHECK: Each table should have module end clamps at each end of the table's beams. (see photo).
NOTE: Quantity of Sunmodule Plus Solar Modules varies with Table Length. See Materials Box above and Table Lengths Description at beginning of manual. SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
53
OBJECTIVE: To install and secure Sunmodule Plus Solar Modules to Tables.
Step 26: Secure all modules OBJECTIVE: To ensure safety and functionality of Sunmodule Plus Solar Modules and Tables 26.1 Once all table construction has been completed, secure all Modules on all Tables with final tightening. Follow Torque table for final tightening: Torque Table Torque Requirements
Nm
ft-lb
Flange Nut Serrated, M8, EC0496
20
15
Flange Nut, M10, SK5017
30
22
Hex Nut Serrated, M12, SA5229
28
21
CONGRATULATIONS! YOU HAVE SUCCESSFULLY INSTALLED THE SOLARWORLD SUNMODULE PLUS SOLAR MODULES ON THE SOLARWORLD SUNFIX GROUND MOUNT TILT LEG VERSION
54
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Production and sales locations of the SolarWorld group Location
Distributor
Rheinfelden
Freidberg
Bonn Grenoble
Madrid Boca Raton Hillsboro
SW-04-6090US 05-2013
Camarillo
Singapore
Cape Town
SolarWorld Ibérica, S.L. C/La Granja 15, Bloque B-1°B 28108 Alcobendas, Madrid Spain
SolarWorld France SAS Hôtel de l‘Entreprise, Petite Halle, Bouchayer-Viallet 31, rue Gustave Eiffel 38000 Grenoble France
SolarWorld Americas LLC 4650 Adohr Lane Camarillo, CA 93012 USA [email protected] solarworld.com
SolarWorld Africa Pty. Ltd. 20th Floor 1 Thibault Square Kapstadt, 8001 South Africa [email protected] solarworld-africa.co.za
SolarWorld AG Martin-Luther-King-Str. 24 53175 Bonn Germany Phone: +49 228 55920 0 Fax: +49 228 55920 99 [email protected] solarworld.de
SolarWorld Asia Pacific Pte. Ltd. 72 Bendemeer Road #07-01, Luzerne Singapore 339941 Singapore
solarworld.com
America's Authority on Solar
May 2013
2
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Table of contents Introduction
5
General guidelines for installation personnel
6
Safety icons
7
General safety precautions and guidelines
8
Safety precautions and guidelines for SolarWorld solar modules
9
Unpacking and checking parts
10
Parts required for installaion
11
Tools required for Sunfix Ground Mount installation
13
Recycling packing materials
14
Checkpoints prior to installaion
15
Pre-installation procedure outline
16 General pre-installation guidelines
16
Example of completed Sunfix Ground Mount system
16
Table row configuration
17
Table assembly order
17
Installation procedure outline
18 Pre-assembly (optional)
18
Pre-assembly list (optional)
19
Step 1: Attach bottom bracket to CIDH or Earth Screw (Detail A)
20
Step 2: Attach inner leg to bottom bracket assembly (Detail B)
21
Step 3: Attach front outer leg to front inner leg assembly (Detail C)
22
Step 4: Attach rear outer leg to rear inner assembly (Detail G)
24
Step 5: Attach angled inner let to rear bottom bracket assembly (Detail F)
26
Step 6: Attach angled outer let to angled inner leg assembly (Detail E)
27
Step 7: Attach top bracket to front & angled leg assemblies (Detail D)
28
Step 8: Attach top bracket to rear let assembly (Detail H)
30
Step 9: Attach girder to top bracket assemblies (Section A-A)
31
Step 10: Secure all materials
33
Step 11: Create rope assembly (Detail J, Detail K)
34
Step 12: Attach rope assemblies to front bracket assemblies (Detail J, Detail K)
36
Step 13: Create rail clamp assembly (pre-assembly)
38
Step 14: Attach splice plates to 3M beam (pre-assembly)
39
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
3
Table of contents (continued)
4
Step 15: Attach lug and bolt set to hole on side of beams
40
Step 16: Secure center beam
41
STep 17: Secure outer beam
42
Step 18: Table assembly order
43
Step 19: Connect 3M beam/splice plate assembly to 7M & 8M long table assemblies
44
Step 20: Attach lug and bolt set to hole on top of beam at row end
45
Step 21: Create mid-clamp w/WEEB assembly for outer horizontal extrusion (pre-assembly)
46
Step22: Create mid-clamp assembly for inner horizontal extrusion (pre-assembly)
47
Step 23: Create end clamp assemblies (pre-assembly)
48
Step 24: Secure extrusions
49
Step 25: Attach Sunmodule Plus solar modules to table assembly
50
Step 26: Secure all modules
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Introduction The SolarWorld Sunfix Ground Mount offers the premiere system for providing clean, environmentally-friendly solar power. This fully functional solar panel system provides much-needed clean, economical and environmentally-safe energy. Thank you for your contribution to the preservation and conservation of the earth. This installation manual provides step-by-step instructions, complete part specifications, safety warnings, and diagrams to successfully construct the Tilt Leg Version of the SolarWorld Sunfix Ground Mount with Sunmodule Plus Solar Modules.
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
5
General guidelines for installation personnel Please read this manual carefully before installing the system and carry out the installation procedures correctly. This manual does not list all precautions needed for safe work. Be sure to follow OSHA guidelines. This manual provides guidelines for installation, but it does not guarantee the quality of installation work. Please complete all work in a responsible and professional manner. Electrical work should be performed by a qualified electrician; this manual is for installation purposes only.
6
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Safety icons Various safety icons appear in this installation manual and on the products it describes. These icons are categorized, according to the consequences of ignoring the icons and handling the products inappropriately.
* * * D A N G E R O F D E AT H F R O M E L E C T R I C S H O C K ! * * * Sunmodule Plus Solar Modules generate electricity as soon as they are exposed to light. The voltage of a single module is less than 50 VDC. When several modules are connected in series, the summed voltage and current can be dangerously high. When the modules are connected in parallel the currents are summed together. Although touch protection is provided in the form of the fully insulated plug contacts, the following points must be observed when handling the Sunmodule Plus Solar Modules to avoid the risk of fire, arcing and fatal electric shock. _
The installation of the higher voltage systems should be done by qualified, licensed professionals.
_
Do not insert electrically conducting parts into the plugs or sockets.
_
Do not wear metallic jewelry while performing mechanical or electrical installation.
_
Do not fit Sunmodule Plus Solar Modules and wiring with wet plugs and sockets.
_
Tools and working conditions must be dry.
_
Exercise extreme caution when carrying out work on wiring and use the appropriate safety equipment (insulated tools, insulated gloves, etc.).
_
Do not use damaged modules! Do not dismantle modules. Do not remove any part or label fitted by the manufacturer! Do not treat the rear of the laminate with paint, adhesives or mark it using sharp objects.
* * * D A N G E R O F D E AT H F R O M E L E C T R I C S H O C K ! * * * The inverter can produce dangerous, high voltages, even when not connected: _
Exercise extreme caution when working on wiring and the Inverter.
_
After switching off the Inverter, it is essential to wait for the time interval specified by the manufacturer before beginning any further work. This allows the high voltage components time to discharge.
_
Be sure carefully to follow the Inverter manufacturer’s Installation Instructions.
* * * D A N G E R O F D E AT H F R O M A R C I N G ! * * *
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
7
General safety precautions and guidelines The Tilt Leg Version of the SolarWorld Sunfix Ground Mount has been load-tested and verified by professional engineers. Testing information can be provided upon request. Always follow OSHA guidelines to prevent accidents; safety regulations must be observed. Always take the following precautions to prevent accidents and injury. Take the following precautions before beginning work: _
Plan the job and visit the site before starting work.
_
On site, do not work alone. Always work with at least one other person. When lifting over 50 lbs is required, work in teams of three. Each Sunmodule Plus Solar Module weighs approximately 50 lbs. Each extrusion weighs approximately 40 lbs to 50 lbs. It is highly recommended that you work in task crews with a minimum of three (3) trained installers for optimum safety and efficiency. See weights and measure specifications.
_
Inspect tools before using them.
Do not work under dangerous conditions: _
When it is raining, or there is a strong probability that it will start raining.
_
When high wind conditions exist, or are expected, or when a high wind warning has been issued.
_
When it is snowing, or when there is snow underfoot.
Wear appropriate work clothes and protective equipment:
8
_
Work clothes for both the upper and lower body should fit well and allow you to move freely.
_
Always wear protective equipment, hard hat, work gloves, steel toe boots, eye protection, etc.
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Safety precautions and guidelines for SolarWorld solar modules _
Do not cut, drill into or modify SolarWorld Sunmodule Plus Solar Modules.
_
Never step or sit on the glass surface of a SolarWorld Sunmodule Plus Solar Modules.
_
Only use the supplied or specified parts to attach the SolarWorld Sunmodule Plus Solar Modules and tables.
_
Only use the tools specified.
_
Do not install near flammable liquids or gases.
_
Do not drop or allow objects to fall onto modules.
_
Do not use damaged modules.
_
Keep the back sides of SolarWorld Sunmodule Plus Solar Modules free of foreign objects.
_
Do not use chemicals on SolarWorld Sunmodule Plus Solar Modules when cleaning.
_
Do not wear metallic jewelry, which may cause electrical shock.
_
Do not expose SolarWorld Sunmodule Plus Solar Modules to concentrated sunlight from mirrors, lenses or similar means.
_
Install SolarWorld Sunmodule Plus Solar Modules and systems according to applicable codes.
_
SolarWorld Sunmodule Plus Solar Modules should be installed and maintained by qualified personnel. Keep unauthorized personnel away.
_
Do not short-circuit SolarWorld Sunmodule Plus Solar Modules output cables.
_
SolarWorld Sunmodule Plus Solar Modules generate electricity when exposed to sunlight.
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
9
Unpacking and checking parts The utmost care is required when handling the modules. Take care when unpacking, transporting, and storing them. Leave modules in packaging until they are to be installed. Carry Sunmodule Plus Solar Modules with both hands. _
Do not use the connection socket as a handle.
_
Do not stand modules on hard or rough ground.
_
Do not stand modules on their corners.
_
Ensure modules do not bow.
_
Do not place modules on top of each other, except as originally packaged from SolarWorld.
_
Do not subject to load, do not stand on them, do not drop.
_
Do not mark or work on them with sharp objects.
_
Keep all electrical contacts clean and dry.
In order to keep a record of your system, we recommend that you make a note of the serial numbers. If necessary to store the modules temporarily, a dry, ventilated room should be used.
10
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Parts required for installation Confirm count of all parts listed below prior to beginning installation. The parts list contains both anodized and non-anodized part descriptions and item numbers. SWCA Part Description
SWCA Part No.
BOTTOM BRACKET 240 mm MIL AL
EC0241
BOTTOM BRACKET 240 mm CLR ANO
EC0895
TOP BRACKET X BRACE MIL AL
EC1005
TOP BRACKET X BRACE CLR ANO
EC1006
U-FOOT PLATE 3/4" BLT MIL AL
EC0586
BOLT HXHD M12X100 DIN 931 A2
SA5227
WASHER FLAT M13 3X37 mm A2, DIN 9021
SA5228
NUT HEX M12 SERR FLANGE A2
SA5229
CLAMP 8 mm DIA ROPE SST
SA5124
THIMBLE 8 mm DIA A4
SA5125
WIRE ROPE 8 mm DIA SST
SA5126
TURNBUCKLE 10 mm A4
SA5127
SHACKLE ROUND M8 A4
SA5128
RING BOLT M10 DIN 580 A2
SK5037
CABLE CLIP ADJUSTABLE-CTR BEAM
EC0531
CABLE TIE 7" UV RES BLK 100PK
EC0399
SCREW PHP#10X3/4 TEK S/S 100PK
EC0400
MOUNT CBL TIE #10SCR 100PK BLK
EC0656
WASHER MOD GND WEEB DPF SST
EC0534
BUR WEEB PMC BOND WASH SST
EC0661
OUTER BEAM 6TBL 3072 mm MIL AL
EC0221
OUTER BEAM 10TBL 5092 mm MIL AL
EC0222
OUTER BEAM 12TBL 6102 mm MIL AL
EC0223
OUTER BEAM 14TBL 7112 mm MIL AL
EC0224
OUTER BEAM 16TBL 8122 mm MIL AL
EC0225
OUTER BEAM 6TBL 3072 mm CLR ANO
EC0705
OUTER BEAM 10TBL 5092 mm CLR ANO
EC0706
OUTER BEAM 12TBL 6102 mm CLR ANO
EC0707
OUTER BEAM 14TBL 7112 mm CLR ANO
EC0708
OUTER BEAM 16TBL 8122 mm CLR ANO
EC0709
GIRDER 2757 mm MIL AL
EC0226
GIRDER 2757 mm CLR ANO
EC0710
GIRDER HD 2757 mm MIL AL
EC0535
GIRDER HD 2757 mm CLR ANO
EC0922
CENTER BEAM 6TBL 3072 mm MIL AL
EC0675
CENTER BEAM10TBL 5092 mm MIL AL
EC0676
Notes
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
11
12
CENTER BEAM12TBL 6102 mm MIL AL
EC0677
CENTER BEAM14TBL 7112 mm MIL AL
EC0678
CENTER BEAM16TBL 8122 mm MIL AL
EC0679
CENTER BEAM6TBL 3072 mm CLR ANO
EC0684
CENTER BEAM10TBL 5092 mm CLR ANO
EC0685
CENTER BEAM12TBL 6102 mm CLR ANO
EC0686
CENTER BEAM14TBL 7112 mm CLR ANO
EC0687
CENTER BEAM16TBL 8122 mm CLR ANO
EC0688
BEAM CLAMP M10 BOLT MIL AL
EC0242
SPACER END CLAMP 30.4 mm MIL AL
EC0263
SPLICE PLATE 300 mm M10 MIL AL
EC0244
WASHER MOD CLAMP M8 4X36 mm A2
SA5079
BOLT HMHD M8X53 W/NOTCH A2
SH0002
NUT HEX M8 SERR FLANGE A2
EC0496
BOLT HMHD M10X30 W/NOTCH A2
SH5004
NUT HEX M10 SERR FLANGE A2
SK5017
NUT BREAK AWAY M8X13 mm A2
SK5068
OUTER LEG 560 mm MIL AL
EC0233
OUTER LEG 880 mm MIL AL
EC0234
OUTER LEG 1260 mm MIL AL
EC0235
OUTER LEG 1560 mm MIL AL
EC0236
OUTER LEG 1860 mm MIL AL
EC0237
INNER LEG 320 mm MIL AL
EC0238
INNER LEG 720 mm MIL AL
EC0239
OUTER LEG 320 mm CLR ANO
EC0880
OUTER LEG 560 mm CLR ANO
EC0881
OUTER LEG 880 mm CLR ANO
EC0882
OUTER LEG 1260 mm CLR ANO
EC0883
OUTER LEG 1560 mm CLR ANO
EC0884
OUTER LEG 1860 mm CLR ANO
EC0885
INNER LEG 320 mm CLR ANO
EC0886
INNER LEG 720 mm CLR ANO
EC0887
OPTIONAL
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Tools required for Sunfix Ground Mount installation Foundation type: Cast-in-drilled-hole (CIDH) or Earth Screws
1. ¾ Imperial Wrench (combination wrench 1-1/8”)
2. Ratcheting Wrench / Deep socket set with a 1-1/8” head size. 3. Impact Gun 4. Metric wrench / socket set with the following head sizes: 13 mm (for M8 T-Bolt), 15 mm (for M10 T-Bolt) 5. Torque wrench with setting range 10 ft-lb to 45 ft-lb 6. Measuring Tape in Millimeters (10 m)
7. 100 Foot Marking String for alignment
8. Anti-Seize Compound 9. 4 Foot Step Ladder 10. Torque Tools: 3/8” Drive for M8 and M10 fasteners 11. Torque Tools: ½” Drive for ¾” fasteners Optional tools for ground mount installation
1. Electric Torque Gun (Used at slow to medium speed only; NEVER high speed)
2. Laser for Alignment
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
13
Recycling packing materials SolarWorld is committed to reduce the effect on the environment from packaging materials used in the manufacturing of photovoltaic arrays. Efforts have been made to reduce the amount of packaging material. SolarWorld only uses recyclable materials and/or arranges for its reuse. The following table describes the proper way to dispose of the different types of packaging materials which will be delivered to the job site: Category
Item
Where Used
Instructions
Contact
Cardboard
Boxes
Small extrusion pieces
Will be recycled by extrusion manufacturer.
None
Hardware
Recycle
None
Drums
Small extrusion pieces
Will be reused by extrusion manufacturer.
Contact SolarWorld for instructions.
Sheet
Outside extrusion bundles
Will be recycled by extrusion manufacturer.
None
Spacers
Inside extrusion bundles
Will be recycled by extrusion manufacturer.
None
Module cardboard
Module pallets
Will be reused by SolarWorld
Contact SolarWorld for instructions.
Paper
UL Documentation
Between each Sunmodule Plus Solar Module
Recycle
Have recycle container on site
Wood
Battens
Around extrusion bundles
Will be recycled by extrusion manufacturer.
Contact SolarWorld for instructions.
Module pallets
Modules
Will be recycled by SolarWorld
Contact SolarWorld for instructions.
Other pallets
Other products
Recycle
None
Wood Spools
Wire and cable
Will be collected by wire supplier
Contact SolarWorld for instructions.
Plastic Straps
Around extrusion bundles, around module bundles, around other pallets.
Recycle
None
Stretch wrap
Module pallets
Dispose
None
Module Installation Instructions
Modules
Will be reused by SolarWorld
None
Dispose
None
Other
Other (foam peanuts, Other black plastic corner protectors, bubble wrap, etc.)
14
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Checkpoints prior to installation _
Verify inventory of all materials and tools for installation
_
Ensure that all T-Bolts have been pre-coated with an anti-seize compound and that T-Bolts are free from debris prior to assembly. (Optional: Pre-coat T-Bolts with an anti-seize compound to avoid galling. Store in a storage bag to protect from debris)
_
Check power tools and hand tools
_
Prior to mounting the SolarWorld Sunmodule Plus Solar Modules, make sure that the electrical junction box is faced toward the Center Beam. The top and bottom solar panels junction box will adjoin in the center. (Note: Junction box is located underneath SolarWorld Logo)
_
When mounting SolarWorld Sunmodule Plus Solar Modules on the Extrusions, make sure the cables are secure, never allow an output cable to become caught between the Extrusion and a module frame. Short circuits and fire can result.
_
Do not remove tape securing the cables until after installation is complete.
_
Prior to mounting Sunmodule Plus Solar Modules, remove and recycle the black plastic protection corners and white foam spacers. (Refer to the Recycling Packing Materials)
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
15
Pre-installation procedure outline General pre-installation guidelines This manual provides installation instructions for installing (1) Tilt Leg Version of the SolarWorld Sunfix Ground Mount and Sunmodule Plus Solar Module Panels for (1) Table at a time. Certain installation parts have multiple specifications, depending on procedure or whether the part is anodized or non-anodized. See table references for details.
Example of completed Sunfix Ground Mount system The following picture shows the completed installation of the Tilt Leg Version Sunfix Ground Mount system:
Pre-installation of cast-in-drilled-hole (CIDH) or Earth screw foundation and table lengths overview
16
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
The Installation Procedure Outline and following Steps provide instructions for how to complete a Table of any length. The part specifications used are for installing a 5M Long Table (10 Modules), 6M Long Table (12 Modules), 7M Long Table (14 Modules), 8M Long Table (16 Modules), and a connecting 3M Long Table (6 Modules). Each series of arrays are referred to as “Tables.” There are five (5) table lengths that will be utilized in the design and construction of this solar panel installation project:
1. 3M Table: 6 Solar Modules = 3 Sunmodule Plus Solar Modules x 2 Rows
2. 5M Table: 10 Solar Modules = 5 Sunmodule Plus Solar Modules x 2 Rows 3. 6M Table: 12 Solar Modules = 6 Sunmodule Plus Solar Modules x 2 Rows 4. 7M Table: 14 Solar Modules = 7 Sunmodule Plus Solar Modules x 2 Rows 5. 8M Table: 16 Solar Modules = 8 Sunmodule Plus Solar Modules x 2 Rows
Table row configuration Three (3) Table Row Configurations are shown below as examples, but many more configurations exist:
1. 46-Panel Table Configuration: 8M-3M-7M-5M
2. 92-Panel Table Configuration: 7M-3M-7M-3M-7M-3M-7M-3M-7M NOTE: The 92-Panel Table Configuration omits 2 Modules in portrait. 3. 138 Module Table Configuration: 8M-3M-7M-3M-7M-3M-7M-3M-7M-3M-7M-3M-8M NOTE: All Table Configuration specifications are described in order from West to East: Complete tables in consecutive order from one end of the row to the other.
Table assembly order
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
17
Installation procedure outline Pre-assembly (optional) Step 1: Attach bottom bracket leg to CIDH (Detail A) or Earth Screw Step 2: Attach inner leg to bottom bracket assembly (Detail B) Step 3: Attach front outer leg to front inner leg assembly (Detail C) Setp 4: Attach rear outer leg to rear inner leg assembly (Detail G) Step 5: Attach angled inner let to rear bottom bracket assembly (Detail F) Step 6: Attach angled outer leg to angled inner leg assembly (Detail E) Step 7: Attach top bracket to front & angled leg assemblies (Detail D) Step 8: Attach top bracket to rear leg assembly (Detail H) Step 9: Attach girder to top bracket assemblies (Section A-A) Step 10: Secure all materials Step 11: Create rope assembly (Detail J, Detail K) Step 12: Attach rope assemblies to front bracket assemblies (Detail J, Detail K) Step 13: Create rail clamp assembly (optional pre-assembly) Step 14: Attach splice plates to 3M outer and center beam (optional pre-assembly) Step 15: Attach lug and bolt set to hole on side of beams Step 16: Secure center beams Step 17: Secure outer beams Step 18: Table assembly order Step 19: Connect 3M center beam/splice plate assembly and outer beam/splice plate assembly to 5M, 6M, 7M, and 8M long table assemblies Step 20: Create mid-clamp w/WEEB assembly for outer beam (optional pre-assembly) Step 21: Create mid-clamp assembly for center beam (optional pre-assembly) Step 22: Create end clamp assemblies (optional pre-assembly) Step 23: Secure all beams Step 24: Attach Sunmodule Plus solar modules to table assembly Step 25: Secure all modules and materials
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Pre-assembly list (optional) Pre-assemblies are subassemblies, which can be assembled on a bench prior to installation in the field. 1. Rail Clamp Assembly A. (1) T-Bolt M10X30 mm, SH5004 B. (1) Rail Clamp 70 mm, EC0242 C. (1) Flange Nut, M10 A2, SK5017 2. Mid-Clamp Assembly w/WEEB for Outer Horizontal Extrusion A. (1) Module Flat Washer (Ø36 mm X 4 mm Thick), SA5079 B. (1) Module T-Bolt (M8X53 mm), SH0002 C. (1) M8 Serrated Flange Hex Nut, EC0496 D. (1) WEEB-DPF, EC0534 3. Mid-Clamp Assembly for Center Beam A. (1) Module Flat Washer (Ø36 mm X 4 mm Thick), SA5079 B. (1) Module T-Bolt (M8X53 mm), SH0002 C. (1) M8 Serrated Flange Hex Nut, EC0496 4. End-Clamp Module w/WEEB Assembly A. (1) M8 Serrated Flange Hex Nut, EC0496 B. (1) End Clamp, EC0263 C. (1) Module Flat Washer (Ø36 mm X 4 mm Thick), SA5079 D. (1) Module T-Bolt (M8X53 mm), SH0002 E. (1) WEEB-PMC, EC0661 5. Splice Plate to 3M Outer Beam or Center Beam A. (1) 3M Outer Beam (3072 mm), EC0221/EC0705 OR (1) 3M Center Beam (3072 mm), EC0675/EC0684 B. (2) Splice Plate, 300 mm, EC0244 C. (4) T-Bolt, M10X30 mm, SH5004 D. (4) Flange Nut, M10 A2, SK5017 6. Top Bracket to Girder A. (2) Top Bracket, EC1005/EC1006 B. (4) T-Bolt M10X30 mm, SH5004 C. (4) Flange Nut, M10 A2, SK5017 D. (1) Girder (2757 mm), EC0226/EC0710 OR Girder HD (2757 mm), EC0535/EC0922
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Step 1: Attach bottom bracket to CIDH or Earth Screw (Detail A) Materials Required for Step 1 (4) Cast In Drilled Hole, (CIDH) or Earth Screw (Supplied by installer) (4) Bottom Bracket, EC0241/ECO895 (4) U-Foot Plate for ¾” Bolt, EC0586 (4) ø3/4” Anchor Bolt, hot dip galvanized (HDG), (Supplied by installer) (4) ø3/4” Flat Washer, HDG, (Supplied by installer) (4) ø3/4” Split Washer, HDG (Supplied by installer) (4) ø3/4” Nut, HDG (Supplied by installer)
1.1 Place (1) Anchor Bolt into CIDH hole or drive (1) Earth Screw into ground. (Refer to User design specification)
1.2 Align (1) Bottom Bracket rectangular hole on top of (1) Anchor Bolt or (1) Earth Screw. QUALITY CHECK: The length of the Bottom Bracket should be secured perpendicular to the length of the table, with the vertically parallel bolt holes facing towards the rear of the table, and the diagonally angled bolt holes facing towards the front of the table.
1.3 Place (1) U-Foot Plate on top of (1) Anchor Bolt or (1) Earth Screw.
1.4 Place (1) Flat Washer on top of (1) U-Foot Plate.
1.5 Place (1) Split Washer on top of (1) Flat Washer.
1.6 Place (1) Nut on top of (1) Split Washer.
NOTE: This creates (1) Bottom Bracket Assembly.
1.7 Repeat Steps 1.1 to 1.6 three (3) times.
OBJECTIVE: Attach (4) Bottom Brackets to (4) CIDH’s or (4) Earth Screws.
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Step 2: Attach inner leg to bottom bracket assembly (Detail B) Materials Required for Step 2 (4) Bottom Bracket Assembly (4) Inner Leg, 720 mm, EC0239/ECO887 (8) Bolt, M12x100 mm, SA5227 (8) Flat Washer, M13 3X37 mm, SA5228 (8) Flange Nut, M12 A2, SA5229 2.1 Place (1) Inner Leg inside (1) Bottom Bracket Assembly at a 90-degree vertical angle. 2.2
Align bottom (2) Inner Leg holes with (2) Bottom Bracket vertically parallel holes.
QUALITY CHECK: Use a Level to confirm angle consistency. 2.3 Insert (2) Flat Washers and (2) Bolts into (2) aligned holes. 2.4 Secure (2) Bolts with (2) Flange Nuts.
QUALITY CHECK: Use a Level to confirm angle consistency.
QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency. NOTE: This creates (1) Inner Leg Assembly. 2.5 Repeat Steps 2.1 to 2.4 three (3) times to attach (4) Inner Legs to (4) Bottom Bracket Leg Assemblies. OBJECTIVE: Attach (4) Inner Legs to (4) Bottom Bracket Assemblies.
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Step 3: Attach front outer leg to front inner leg assembly (Detail C) Materials Required for Step 3 (2) Front Inner Leg Assembly (2) Front Outer Leg, 560 mm, EC0233/ECO881 (4) Flat Washer, M13 3X37 mm, SA5228 (4) Bolt, M12x100 mm, SA5227 (4) Flange Nut, M12 A2, SA5229 3.1 Place (1) Front Outer Leg on top of (1) Inner Leg Assembly and lower until (2) Outer Leg holes are aligned with (2) Inner Leg holes. NOTE: Refer to “Chart 1” to determine part specification for Front Outer Leg. NOTE: Refer to “Chart 2” for angle and length measurements to determine hole alignment. 3.2 Insert (2) Flat Washers and (2) Bolts into (2) Outer Leg holes aligned with (2) Inner Leg holes. 3.3 Secure (2) Bolts with (2) Flange Nuts.
NOTE: This creates 1 Front Leg Assembly. 22
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
QUALITY CHECK: Use a Level to confirm angle consistency.
QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency.
QUALITY CHECK: See Torque table for final tightening specifications. 3.4 Repeat Steps 3.1 to 3.3 one (1) time.
OBJECTIVE: Attach (2) Front Outer Legs to (2) Inner Leg Assemblies.
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Step 4: Attach rear outer leg to rear inner assembly (Detail G) Materials Required for Step 4 (2) Rear Inner Leg Assembly (2) Rear Outer Leg, (See “Chart 1” for part specification) (4) Flat Washer, M13 3X37 mm, SA5228 (4) Bolt, M12x100 mm, SA5227 (4) Flange Nut, M12 A2, SA5229 4.1 Place (1) Rear Outer Leg on top of (1) Inner Leg Assembly and lower until (2) Outer Leg holes are aligned with (2) Inner Leg holes. NOTE: Refer to “Chart 1” to determine part specification for Rear Outer Leg. NOTE: Refer to “Chart 2” for angle and length measurements to determine hole alignment. 4.2 Insert (2) Flat Washers and (2) Bolts into (2) Outer Leg holes aligned with (2) Inner Leg holes. 4.3 Secure (2) Bolts with (2) Flange Nuts.
NOTE: This creates 1 Rear Leg Assembly.
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
QUALITY CHECK: Use a Level to confirm angle consistency.
QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency.
QUALITY CHECK: See Torque table for final tightening specifications. 4.4 Repeat Steps 4.1 to 4.3 one (1) time.
OBJECTIVE: Attach (2) Rear Outer Legs to (2) Inner Leg Assemblies. SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Step 5: Attach angled inner leg to rear bottom bracket assembly (Detail F) Materials Required for Step 5 (2) Rear Bottom Bracket Assembly (2) Inner Leg, 720 mm, EC0239/ECO887 (4) Flat Washer, M13 3X37 mm, SA5228 (4) Bolt, M12x100 mm, SA5227 (4) Flange Nut, M12 A2, SA5229 5.1 Place (1) Inner Leg inside (1) Rear Bottom Bracket.
5.2 Align bottom (2) Inner Leg holes with (2) Bottom Bracket diagonally angled holes. 5.3 Insert (2) Flat Washers and (2) Bolts into (2) aligned holes. 5.4 Secure (2) Bolts with (2) Flange Nuts.
NOTE: This creates 1 Angled Inner Leg Assembly. QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency. 5.5 Repeat Steps 5.1 to 5.4 one (1) time. OBJECTIVE: Attach (2) Inner Legs to (2) Rear Bottom Bracket Assemblies.
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Step 6: Attach angled outer leg to angled inner leg assembly (Detail E) Materials Required for Step 6 (2) Angled Inner Leg Assembly (2) Angled Outer Leg, (See “Chart 1” for part specification) (4) Flat Washer, 3x37 mm, SA5228 (4) Bolt, M12x100 mm, SA5227 (4) Flange Nut, M12 A2, SA5229 6.1 Place (1) Angled Outer Leg on top of (1) Angled Inner Leg Assembly and lower until (2) Outer Leg holes are aligned with (2) Inner Leg holes. NOTE: Refer to “Table 1” to determine part specification for Rear Outer Leg. NOTE: Refer to “Chart 2” for angle and length measurements to determine hole alignment. 6.2 Insert (2) Flat Washers and (2) Bolts into (2) Outer Leg holes aligned with (2) Inner Leg holes. 6.3 Secure (2) Bolts with (2) Flange Nuts.
NOTE: This creates 1 Angled Leg Assembly. QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency.
QUALITY CHECK: See Torque table for final tightening specifications. 6.4 Repeat Steps 6.1 to 6.3 one (1) time
OBJECTIVE: Attach (2) Angled Outer Legs to (2) Angled Inner Leg Assemblies. SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Step 7: Attach top bracket to front & angled leg assemblies (Detail D) Materials Required for Step 7 (2) Top Bracket, EC1005/EC1006 (2) Front Leg Assembly (2) Angled Leg Assembly (8) Flat Washer, M13 3X37 mm, SA5228 (8) Bolt, M12x100 mm, SA5227 (8) Flange Nut, M12 A2, SA5229 7.1 Place (1) Top Bracket on top of (1) Front Leg Assembly, and align (2) Top Bracket holes with (2) Front Leg holes.
7.2 Insert (2) Flat Washers and (2) Bolts into (2) Top Bracket holes aligned with (2) Front Leg holes.
7.3 Secure (2) Bolts with (2) Flange Nuts by finger-tightening ONLY.
NOTE: Adjust by finger-tightening to allow adjustments for securing Girder in Step 9. QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency. 7.4 Place other end of Top Bracket on top of (1) Angled Leg Assembly, and align (2) Top Bracket holes with (2) Angled Leg holes.
7.5 Insert (2) Flat Washers and (2) Bolts into (2) Top Bracket holes aligned with (2) Angled Leg holes.
7.6 Secure (2) Bolts with (2) Flange Nuts by finger-tightening ONLY.
NOTE: Adjust by finger-tightening to allow adjustments for securing Girder in Step 9.
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency.
7.7 Confirm 90 degree vertical angle of Front Leg Assembly with Level.
7.8 Torque (2) Bolts on (1) Front Bottom Bracket. QUALITY CHECK: See Torque table for final tightening specifications.
NOTE: Do NOT torque Top Bracket Bolts. This creates 1 Front Top Bracket Assembly.
7.9 Repeat Steps 7.1 to 7.8 (1) time.
OBJECTIVE: Attach (2) Top Brackets to (2) Front Leg Assemblies and (2) Angled Leg Assemblies. SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Step 8: Attach top bracket to rear leg assembly (Detail H) Materials Required for Step 8 (2) Top Bracket, EC1005/EC1006 (2) Rear Leg Assembly (4) Flat Washer, M13 3X37 mm, SA5228 (4) Bolt, M12x100 mm, SA5227 (4) Flange Nut, M12 A2, SA5229 8.1 Place (1) Top Bracket on top of (1) Rear Leg Assembly, and align (2) Top Bracket holes with (2) Rear Leg holes. QUALITY CHECK: The extra holes on the Top Bracket should face away from the Table. 8.2 Insert (2) Flat Washers and (2) Bolts into the (2) Top Bracket holes aligned with (2) Rear Leg holes. 8.3 Secure (2) Bolts with (2) Flange Nuts by finger-tightening ONLY. QUALITY CHECK: Bolts should face towards center of table for aesthetic consistency.
QUALITY CHECK: Flange Nuts should face the same direction for aesthetic consistency. NOTE: Adjust by finger-tightening to allow adjustments for securing Girder in Step 9. 8.4 Confirm 90 degree vertical angle of Rear Leg Assembly with Level. 8.5 Torque (2) Bolts on (1) Rear Bottom Bracket. QUALITY CHECK: See Torque table for final tightening specifications.
NOTE: Do NOT torque Top Bracket Bolts. NOTE: This creates 1 Rear Top Bracket Assembly. 8.6 Repeat Steps 8.1 to 8.5 one (1) time. OBJECTIVE: Attach (2) Top Brackets to (2) Rear Leg Assemblies. 30
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Step 9: Attach girder to top bracket assemblies (Section A-A) Materials Required for Step 9 (2) Girder HD, 2757 mm, EC0535/EC0922 or Girder, 2757 mm, EC0226/EC0710 (8) T-Bolt, M10x30 mm, SH5004 (8) Hex Nut, M10, SK5017 (2) Front Top Bracket Assembly (2) Rear Top Bracket Assembly 9.1 Place (1) Girder on top of (1) Front Top Bracket Assembly and (1) Rear Top Bracket Assembly. NOTE: Refer to “Chart 2” to determine overhang measurements. QUALITY CHECK: Use measuring tape to verify distances. 9.2 Place (2) T-Bolt heads into (2) Front Top Bracket holes with T-Bolt heads facing towards Girder, and rotate (2) Bolts 90 degrees. QUALITY CHECK: Indentation line on bottom of T-Bolt body should be perpendicular to Girder. 9.3 Secure (2) T-Bolts by screwing (2) Hex Nuts onto bottom of (1) Front Top Bracket. 9.4 Rotate (1) Rear Top Bracket parallel to (1) Girder. 9.5 Place (2) T-Bolt heads into (2) Rear Top Bracket holes with T-Bolt heads facing towards Girder, and rotate (2) T-Bolts 90 degrees. QUALITY CHECK: Indentation line on bottom of T-Bolt body should be perpendicular to Girder. 9.6 Secure (2) T-Bolts by screwing (2) Hex Nuts onto bottom of (1) Rear Top Bracket.
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9.7 Reconfirm 90 degree vertical angle of Front and Rear Leg Assembly with Level. 9.8 Repeat Steps 9.1 to 9.8 one (1) time. QUALITY CHECK: Refer to “Chart 3” to confirm Girder overhang measurements. 9.9 Torque Top Bracket T-Bolts. QUALITY CHECK: See Torque table for final tightening specifications. OBJECTIVE: Attach (2) Girders to (4) Top Bracket Assemblies.
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Step 10: Secure all materials 10.1 Once all table construction has been completed, torque all materials. Torque Table Torque Requirements
Nm
ft-lb
Flange Nut Serrated, M8, EC0496
20
15
Flange Nut, M10, SK5017
30
22
Hex Nut Serrated, M12, SA5229
28
21
QUALITY CHECK: Confirm torque specifications for previously torqued materials.
OBJECTIVE: To ensure safety and functionality of Ground Mount.
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Step 11: Create rope assembly (Detail J, Detail K) Materials Required for Step 11 (8) Ring Bolt, M10, SK5037 (12) Shackle Body, M8, SA5128 (12) Shackle Pin, M8, SA5128 M8, SA5128 (4) Turnbuckle, 10 mm, SA5127 (8) Thimble, 8 mm DIA ROPE SST, SA5125 (32) Clamp Assembly, 8 mm DIA ROPE SST, SA5124 (4) M8 Wire Rope, 8 mm DIA SST, SA5126 NOTE: U-Bolt, Saddle and Hex Nut are referred to as Clamp Assembly. 11.1 Insert end of (1) Wire Rope into (4) Clamp Assemblies. Fold end of wire Rope with approximately 200 mm of overlap, and place (1) Thimble underneath Rope bend. NOTE: Rope overhang of 200 mm should begin after Thimble. 11.2 Position (1) Clamp Assembly adjacent to (1) Thimble, and secure Clamp Assembly with (2) Hex Nuts. NOTE: Saddle should be secured on long side of rope. 11.3 Position remaining (3) Clamp Assemblies approximately 50 mm away each from (1) secured Clamp Assembly, and secure with (6) Hex Nuts. QUALITY CHECK: Remaining Rope overhang should be approximately 50 mm. 11.4 Cut Rope overhang at approximately 200 mm from last Clamp Assembly. 11.5 Insert (1) Shackle Body into (1) Thimble. 11.6 Insert (1) Turnbuckle end into (1) Shackle Body, and secure by inserting (1) Shackle Pin into (1) Shackle Body. 11.7 Insert another (1) Shackle Body into (1) Ring Bolt. 11.8 Insert other end of (1) Turnbuckle into (1) Shackle, and secure by inserting (1) Shackle Pin into (1) Shackle Body.
NOTE: This creates 1 Turnbuckle Assembly. 11.9 Insert end of (1) Wire Rope into (4) Clamp Assemblies. Fold end of Rope with approximately 200 mm of overlap, and place Thimble underneath Rope bend. NOTE: Rope overhang of 200 mm should begin after Thimble. 34
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Step 11: Create rope assembly continued (Detail J, Detail K) 11.10 Position (1) Clamp Assembly adjacent to Thimble, and secure with (2) Hex Nuts. 11.11 Position remaining (3) Clamp Assemblies approximately 50 mm away each from (1) secured Clamp Assembly, and secure with (6) Hex Nuts. 11.12 Cut Rope overhang at approximately 200 mm from last Clamp Assembly. 11.13 Insert (1) Shackle Body into (1) Ring Bolt. 11.14 Insert (1) Shackle Body with Ring Bolt into (1) Thimble, and secure by inserting (1) Shackle Pin into (1) Shackle Body.
NOTE: This creates 1 Rope Assembly. 11.15 Repeat Steps 11.1 to 11.14 three (3) times. OBJECTIVE: Create (4) Rope Assemblies.
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Step 12: Attach rope assemblies to front bracket assemblies (Detail J, Detail K) Materials Required for Step 12 (4) Rope Assemblies (8) Hex Nut, M10 Serrated Flange A2, SK5017 (2) Front Top Bracket Assembly (2) Front Bottom Bracket Assembly 12.1 Insert (1) Ring Bolt on end of (1) Turnbuckle Assembly into center hole of (1) Front Top Bracket. 12.2 Secure (1) Ring Bolt with (1) Hex Nut. 12.3 Insert (1) Ring Bolt on other end of (1) Rope Assembly into center hole of (1) Front Bottom Bracket on adjacent front leg of the Table. 12.4 Secure (1) Ring Bolt with (1) Hex Nut.
QUALITY CHECK: The (1) Rope Assembly should form a diagonal angle from the top front of the Table to the bottom front of the Table. 12.5 Insert (1) Ring Bolt on end of (1) Turnbuckle Assembly into center hole of other (1) Front Top Bracket. 12.6 Secure (1) Ring Bolt with (1) Hex Nut. 12.7 Insert (1) Ring Bolt on other end of (1) Rope Assembly into center hole of other (1) Front Bottom Bracket on adjacent front leg of the Table. 12.8 Secure (1) Ring Bolt with (1) Hex Nut.
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
QUALITY CHECK: The (2) Rope Assemblies should form crisscrossing, diagonal angles from the top fronts of the Table to the bottom fronts of the Table. 12.9 Wait until all Extrusions are secured in Step 17 to adjust tightness of (2) Turnbuckle Assemblies until no longer slack.
NOTE: Turnbuckle automatically loosens upon reaching maximum tightness. OBJECTIVE: Attach (2) Rope Assemblies to (4) Front Bracket Assemblies. SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Step 13: Create rail clamp assembly (pre-assembly) Materials Required for Step 13 (12) Flange Nut, M10 A2, SK5017 (12) Rail Clamp, 70 mm, EC0242 (12) T-Bolt, M10X30 mm, SH5004
13.1 Place (1) T-Bolt inside (1) Rail Clamp with grooves pointing towards T-Bolt. 13.2 Screw (1) Flange Nut loosely on top of Rail Clamp. NOTE: This creates (1) Rail Clamp Assembly. 13.3 Repeat Steps 13.1-13.2 eleven (11) times. Materials Required for 5M and 6M Long Table: (6) Flange Nut, M10 A2, SK5017 (6) Rail Clamp, 70 mm, EC0242 (6) T-Bolt, M10X30 mm, SH5004 13.4 Repeat Steps 13.1-13.2 six (6) times. OBJECTIVE: Create Rail Clamp Assemblies to secure Beams in Steps 16-17.
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Step 14: Attach splice plates to 3M beam (pre-assembly) Materials Required for 7M, and 8M Long Table: (2) Outer Beam, 3072 mm, EC0221/EC0705 (1) Center Beam, 3072 mm, EC0675/EC0684 (6) Splice Plate, 300 mm, EC0244 (12) T-Bolt, M10X30 mm, SH5004 (12) Flange Nut, M10 A2, SK5017
14.1 Slide (1) Splice Plate with angles facing up halfway under the bottom of (1) Outer Beam. 14.2 Place (2) T-Bolts heads into (2) holes on (1) Splice Plate and rotate 90 degrees. 14.3 Secure (4) T-Bolts by screwing (4) Flange Nuts onto bottom of (1) Splice Plate. NOTE: This creates (1) 3M Beam/Splice Plate Assembly. 14.4 Repeat Steps 14.1 to 14.3 five (5) times. OBJECTIVE 1: Provide the foundation to connect the Beam for the 3M Long Table to 5M, 6M, 7M, and 8M Long Table. OBJECTIVE 2: To use as measuring stick for Beams in Steps 16-17.
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Step 15: Attach lug and bolt set to hole on side of beams Materials Required for 5M, 6M, 7M and 8M Long Table: (6) Lay-In Lug, EC1057 (6) Bolt Set (Serrated Washer, Washer, Bolt, & Nut), EC0149 15.1 Align (1) Lay-In Lug hole with (1) ¼” pre-drilled hole on the side of (1) Beam of each table. 15.2 Align (1) Washer with (1) Lay-In Lug top hole, and place (1) Bolt inside (1) Lay-In Lug top Hole. 15.3 Align (1) Serrated Washer under (1) Lay-In Lug bottom hole. 15.4 Secure (1) Bolt by screwing (1) Nut onto inside wall of (1) Beam. 15.5 Align (1) Lay-In Lug hole with (1) ¼” pre-drilled hole on the other side of same (1) Beam of each table. 15.6 Align (1) Washer with (1) Lay-In Lug top hole, and place (1) Bolt inside (1) Lay-In Lug top Hole. 15.7 Align (1) Serrated Washer under (1) Lay-In Lug bottom hole. 15.8 Secure (1) Bolt by screwing (1) Nut onto inside wall of (1) Beam. 15.9 Repeat Steps 15.1-15.8 for each of remaining (2) Beams per (1) Table. OBJECTIVE: Attach Lugs and Bolt Sets to pre-drilled holes on sides of 3 Beams per (1) Table.
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Step 16: Secure center beam Materials Required for 5M, 6M, 7M, and 8M Long Table: (1) Center Beam, (refer to "Chart 1") (4) Rail Clamp Assemblies
16.1 Place (1) Center Beam across the center of (2) Girders, with approximately 51.5” (1308 mm) from the edge of the Girders. Use a laser to align all Center Beams in each row. 16.2 Secure (1) Center Beam by attaching (1) Rail Clamp Assembly below and against the Center Beam on top of each Girder and finger-tighten. 16.3 Place (1) Rail Clamp Assembly above and against the Center Beam on top of each Girder and finger-tighten. QUALITY CHECK: The Center Beam should be centered on the Girders, approximately 51.5” (1308 mm) from the edge of the Vertical Girders. Use measuring tape to verify distance. QUALITY CHECK: For end tables only, the Center Beam should have a horizontal overhang extending approximately 37.5” (952.5 mm) past the Girders. Note: 8M tables will extend further toward the row end. Use measuring tape to verify distance.
QUALITY CHECK: Use a String Line or Laser to confirm angle consistency. OBJECTIVE: To secure the Center Beam exactly in the middle of the Girders with enough overhang to attach the 3M Horizontal Extrusions.
Step 17: Secure outer beam SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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Materials Required for 5M, 6M, 7M, and 8M Long Table: (2) Outer Beam, (refer to "Chart 1") (8) Rail Clamp Assemblies
17.1 Place (2) Rail Clamp Assemblies on top of (2) Girders approximately ¼” from the bottom and secure by finger- tightening. 17.2 Place (1) Outer Beam above and against the (2) Rail Clamp Assemblies. 17.3 Place (2) Rail Clamp Assemblies on top of (2) Girders above and against (1) Outer Beam and secure by finger- tightening. 17.4 Repeat Steps 17.1-17.3 to secure the top Outer Beam by first attaching (2) Rail Clamp Assemblies approximately ¼” from the top of (2) Girders. NOTE: The completion of this step creates (1) Table Assembly (5M, 6M 7M, or 8M length). 17.5 Adjust tightness of (2) Turnbuckle Assemblies until no longer slack (See Step 12 for review). QUALITY CHECK: The Rail Clamp Assemblies for the Outer Beam should be at a ¼” distance from the bottom and top edges of the Girders. Use measuring tape to verify distance.
QUALITY CHECK: The Outer Beam should extend approximately 37.5’’ (952.5 mm) to the inside of the row. Note: 8M tables will extend further toward the row end. Use measuring tape to verify distance.
QUALITY CHECK: Use (1) 3M Beam /Splice Plate Assembly as a measuring stick to confirm that the 37.5” (952.5 mm) overhang distance for Beam on adjacent tables is sufficient to fit 3M Beams.
QUALITY CHECK: Use a String-line or Laser to confirm angle consistency. OBJECTIVE: To secure the Outer Beams.
Step 18: Table assembly order
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
The following is an example of the table configurations, but there are many possible configuration options. 18.1 Start at one end of the row (7M Table or 8M Table only) and move to the other end. First install the 8M End Table, then the adjacent 7M Table, using the 3M Beam as a spacer. Next install the adjacent 7M Table and continue installing adjacent tables until the end of the row is reached. The last table installed is the 5M or 6M Table, if applicable. Please see the diagram below. QUALITY CHECK: Use 3M Beams with Splice Plates as spacers with 1/4" in between the ends of the beams.
QUALITY CHECK: Use a String line or Laser to confirm angle consistency.
QUALITY CHECK: Use 3M Beam as a spacer for 7M and 8M Tables
OBJECTIVE: Install all Table Assemblies prior to installation of 3M Table Leafs in Step 19 and Sunmodule Plus Solar Modules in Step 24.
Step 19: Connect 3M beam/splice plate assembly to 7M and 8M long table assemblies
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Note: Prior to beginning Step 19, all 7M and 8M Table Assemblies should be installed. Materials Required for 7M and 8M Long Table: (2) Table Assembly, (7M or 8M Long) (6) 3M Beam/Splice Plate Assembly
19.1 Place (1) 3M Beam/Splice Plate Assembly in between (2) Beams from (2) Table Assemblies, with the Splice Plates on the bottom. 19.2 Place (4) T-Bolts heads into (4) remaining holes on (2) Splice Plate Assemblies and rotate 90 degrees. 19.3 Secure (4) T-Bolts by screwing (4) Flange Nuts onto bottoms of (2) Splice Plate Assemblies. 19.4 Repeat Steps 19.1 to 19.3 three (3) times. NOTE: This creates (1) 3M Table Leaf. 19.5 Install all 3M Beam/Splice Plate Assemblies to all Table Assemblies prior to Step 24. NOTE: All 3M Table Leafs should be installed prior to placement of Sunmodule Plus Solar Modules in Step 24. OBJECTIVE: Connect 3M Beam/Splice Plate Assemblies to Table Assemblies to create (1) 3M Table Leaf.
Step 20: Attach lug and bolt set to hole on top of beam at row end 44
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Materials Required for 5M, 6M, 7M and 8M Long Table: (6) EC1057 Lay-In Lug (6) ECO149 Bolt Set (Serrated Washer, Washer, Bolt, & Nut) 20.1 At the end of the row, drill a ¼” hole approximately ½” away from the end of (1) Beam on the top surface. Please note that newer versions of the Beams have this hole prefabricated. 20.2 Align (1) Lay-In Lug hole with (1) ¼” pre-drilled hole at the end (1) Beam of table at end of row. 20.3 Align (1) Washer with (1) Lay-In Lug top hole, and place (1) Bolt inside (1) Lay-In Lug top Hole. 20.4 Align (1) Serrated Washer under (1) Lay-In Lug bottom hole. 20.5 Secure (1) Bolt by screwing (1) Nut onto inside wall of (1) Beam.
20.6 Repeat Steps 20.1-20.5 one (1) time for the other end of Table row. OBJECTIVE: Attach Lugs and Bolt Sets to pre-drilled holes on top of beams at row ends.
Step 21: Create mid-clamp w/WEEB assembly for outer horizontal extrusion (pre-assembly)
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Materials Required for 8M Long Table: (14) M8 Serrated Flange Hex Nut, EC0496 (14) Module Flat Washer, 36 mm X 4 mm, SA5079 (14) Module T-Bolt M8X53 mm, SH0002 (14) WEEB-DPF, EC0534
Materials Required for 7M Long Table: (12) M8 Serrated Flange Hex Nut, EC0496 (12) Module Flat Washer, 36 mm X 4 mm, SA5079 (12) Module T-Bolt M8X53 mm, SH0002 (12) WEEB-DPF, EC0534
Materials Required for 6M Long Table: (10) M8 Serrated Flange Hex Nut, EC0496 (10) Module Flat Washer, 36 mm X 4 mm, SA5079 (10) Module T-Bolt M8X53 mm, SH0002 (10) WEEB-DPF, EC0534
Materials Required for 5M Long Table: (8) M8 Serrated Flange Hex Nut, EC0496 (8) Module Flat Washer, 36 mm X 4 mm, SA5079 (8) Module T-Bolt M8X53 mm, SH0002 (8) WEEB-DPF, EC0534
Materials Required for 3M Leaf Table: (4) M8 Serrated Flange Hex Nut, EC0496 (4) Module Flat Washer, 36 mm X 4 mm, SA5079 (4) Module T-Bolt M8X53 mm, SH0002 (4) WEEB-DPF, EC0534 21.1 Place (1) Module T-Bolt inside (1) WEEB-DPF. Place (1) Module Flat Washer on top of (1) WEEB-DPF. 21.2 Screw (1) M8 Serrated Flange Hex Nut loosely on top of (1) Module Flat Washer. 21.3 Repeat Steps 21.1-21.2 the number of times listed in the material box, depending on table size to create (X) Rail Clamp Assemblies. For example, a 7M Long Table requires (12) Inner Module Assemblies. OBJECTIVE: Create Mid-Clamp w/WEEB Assemblies to secure Sunmodule Plus Solar Modules in Step 14.
Step 22: Create mid-clamp assembly for inner horizontal extrusion (pre-assembly) 46
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
Materials Required for 8M Long Table: (16) M8 Serrated Flange Hex Nut, EC0496 (16) Module Flat Washer, 36 mm X 4 mm, SA5079 (16) Module T-Bolt M8X53 mm, SH0002
Materials Required for 7M Long Table: (14) M8 Serrated Flange Hex Nut, EC0496 (14) Module Flat Washer, 36 mm X 4 mm, SA5079 (14) Module T-Bolt M8X53 mm, SH0002
Materials Required for 6M Long Table: (12) M8 Serrated Flange Hex Nut, EC0496 (12) Module Flat Washer, 36 mm X 4 mm, SA5079 (12) Module T-Bolt M8X53 mm, SH0002
Materials Required for 5M Long Table: (10) M8 Serrated Flange Hex Nut, EC0496 (10) Module Flat Washer, 36 mm X 4 mm, SA5079 (10) Module T-Bolt M8X53 mm, SH0002
Materials Required for 3M Leaf Table: (6) M8 Serrated Flange Hex Nut, EC0496 (6) Module Flat Washer, 36 mm X 4 mm, SA5079 (6) Module T-Bolt M8X53 mm, SH0002 22.1 Place (1) Module T-Bolt inside (1) Module Flat Washer. 22.2 Screw (1) M8 Serrated Flange Hex Nut loosely on top of Flat Washer. 22.3 Repeat Steps 23.1-23.2 the number of times listed in the Materials box, depending on table size to create (X) Rail Clamp Assemblies. For example, a 7M Long Table requires (14) Inner Module Assemblies. OBJECTIVE: Create Mid-Clamp Assemblies to secure Sunmodule Plus Solar Modules in Step 25.
Step 23: Create end clamp assemblies (pre-assembly)
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Materials Required for all Tables: (4) Module T-Bolt M8X53 mm, SH0002 (4) Module Flat Washer, 36 mm X 4 mm Thick, SA5079 (4) End Clamp, EC0263 (4) M8 Serrated Flange Hex Nut, EC0496 (4) WEEB-PMC, EC0661 23.1 Place (1) Module T-Bolt inside (1) WEEB-PMC and (1) End Clamp, followed by (1) Module Flat Washer. 23.2 Screw (1) M8 Serrated Flange Hex Nut loosely on top of Flat Washer. This creates (1) End Clamp Assembly. 23.3 Repeat Steps 23.1-23.2 three (3) times to create (4) End Clamp Assemblies. OBJECTIVE: Create End Clamp Assemblies to secure Sunmodule Plus Solar Modules in Step 25.
Step 24: Secure extrusions 48
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
24.1 Once all table construction has been completed, secure all Extrusions on all Tables with final tightening. Follow Torque table for final tightening: Torque Table Torque Requirements
Nm
ft-lb
Flange Nut Serrated, M8, EC0496
20
15
Flange Nut, M10, SK5017
30
22
Hex Nut Serrated, M12, SA5229
28
21
OBJECTIVE: To ensure safety and functionality of Sunmodule Plus Solar Modules and Tables.
Step 25: Attach Sunmodule Plus solar modules to table assembly
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NOTE: Prior to beginning STEP 25, all 3M Table Leafs should be installed. Materials Required for 8M Long Table: (1) Table Assembly (8M Long) (16) Sunmodule Plus Solar Module, 31 mm (14) Mid-Clamp w/WEEB Assemblies (16) Mid-Clamp Assemblies (4) End Clamp w/WEEB Assemblies
Materials Required for 7M Long Table: (1) Table Assembly (7M Long) (14) Sunmodule Plus Solar Module, 31 mm (12) Mid-Clamp w/WEEB Assemblies (14) Mid-Clamp Assemblies (4) End Clamp w/WEEB Assemblies
Materials Required for 6M Long Table: (1) Table Assembly (6M Long) (12) Sunmodule Plus Solar Module, 31 mm (10) Mid-Clamp w/WEEB Assemblies (12) Mid-Clamp Assemblies (4) End Clamp w/WEEB Assemblies
Materials Required for 5M Long Table: (1) Table Assembly (5M Long) (10) Sunmodule Plus Solar Module, 31 mm (8) Mid-Clamp w/WEEB Assemblies (10) Mid-Clamp Assemblies (4) End Clamp w/WEEB Assemblies
Materials Required for 3M Long Table Leaf: (1) 3M Table Leaf (6) Sunmodule Plus Solar Module, 31 mm (4) Mid-Clamp w/WEEB Assemblies (6) Mid-Clamp Assemblies (4) End Clamp w/ WEEB Assemblies 25.1 Starting at the end of one table, place (1) Sunmodule Plus Solar Module in between the top Outer Beam and the Center Beam, approximately 2” from the ends. The Solar Module should rest against the groove of the Center Beam. Position module in the East/West direction so that the back of the End Clamp is flush with the end of the Outer Beam.
Step 25: Continued: Attach Sunmodule Plus solar modules to table assembly 50
SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
QUALITY CHECK: The top Sunmodule Plus Solar Module should show the SolarWorld logo upside down at the bottom next to the Center Beam, with Junction Box resting on the Center Beam.
25.2 Secure (1) Sunmodule Plus Solar Module by placing (1) End Clamp Assembly at the end of the top Outer Beam. Place the Module T-Bolt upside down into the groove. Rotate the Module T-Bolt 90 degrees and finger-tighten the M8 Serrated Flange Hex Nut. QUALITY CHECK: To ensure that the End Clamp Assembly is secured, the line on the M8 Serrated Flange Hex Nut should be perpendicular to the Beam. Note: See photo for the positioning of end clamp which is flush with the beam. 25.3 Place a second Sunmodule Plus Solar Module in between the bottom Outer Beam and the Center Beam, leaving approximately 2” from the ends.
QUALITY CHECK: The bottom Sunmodule Plus Solar Module should show the SolarWorld logo at the top next to the Center Beam, with Junction Box resting on the Center Beam.
25.4 Secure the bottom Sunmodule Plus Solar Module by placing (1) End Clamp Assembly at the end of the bottom Outer Beam. Place the Module T-Bolt upside down into the groove. Rotate the Module T-Bolt 90 degrees and finger-tighten the M8 Serrated Flange Hex Nut.
Step 25 continued: Attach Sunmodule Plus solar modules to table assembly
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25.5 Place (2) Mid-Clamp Assemblies on the Center Beam, in the middle of the 2nd cell outlined on the tops of the Sunmodule Plus Solar Module. Place the Module T-Bolt upside down into the groove. Rotate the Module TBolt 90 degrees and finger-tighten the M8 Serrated Flange Hex Nut.
QUALITY CHECK: To ensure that the Inner Module Assembly Clamp is secured, the line on the M8 Module T-Bolt should be perpendicular to the Beam.
25.6 Place (2) Mid-Clamp w/WEEB Assemblies on the Outer Beams, against the side of (2) Sunmodule Plus Solar Modules opposite the (2) End Clamp Assemblies. Place the (2) Module T-Bolts upside down into the groove and rotate the Module T-Bolts 90 degrees. Lift (2) Sunmodule Plus Solar Module slightly to fit (2) WEEBs underneath. NOTE: Do not finger-tighten (2) M8 Serrated Flange Hex Nuts until adjacent Sunmodule Plus Solar Modules have been secured. QUALITY CHECK: Use a 5/16” Spacer or spare Module T-Bolt to measure ¼” distance between additional Sunmodule Plus Solar Modules prior to installation. Secure the (2) M8 Serrated Flange Hex Nuts by finger-tightening. QUALITY CHECK: To ensure that the Mid-Clamp Assembly is secured, the line on the M8 Module T-Bolt should be perpendicular to the Beam. 25.7 Place a third Sunmodule Plus Solar Module in between the top Outer Beam and the Center Beam, with a 5/16” measured gap, using Spacer or spare Module T-Bolt, between the adjacent (1) Sunmodule Plus Solar Module. The Sunmodule Plus Solar Module should rest against the groove of the Center Beam.
Step 25 continued: Attach Sunmodule Plus solar modules to table assembly
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SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
QUALITY CHECK: The Module Flat Washer from the Mid-Clamp w/WEEB Assembly should rest atop the third Solar Panel.
25.8
Secure third Sunmodule Plus Solar Module by finger-tightening (1) M8 Serrated Flange Hex Nuts on the MidClamp w/WEEB Assembly.
25.9
Place a fourth Sunmodule Plus Solar Module in between the bottom Outer Beam and the Center Beam, with a ¼” measured gap between the adjacent (1) Sunmodule Plus Solar Module.
QUALITY CHECK: The bottom Sunmodule Plus Solar Module should show the SolarWorld logo at the top next to the Center Beam, with Junction Box resting on the Center Beam. 25.10 Secure the fourth Sunmodule Plus Solar Module by finger-tightening (1) M8 Serrated Flange Hex Nuts on the Mid-Clamp w/WEEB Assembly. 25.11 Place (2) Mid-Clamp Assemblies on the Center Beam, in the middle of the 2nd squares outlined on the tops of the Sunmodule Plus Solar Module. Place the Module T-Bolt upside down into the groove. Rotate the Module T-Bolt 90 degrees and finger-tighten the M8 Serrated Flange Hex Nut. QUALITY CHECK: To ensure that the Mid-Clamp Assembly is secured, the line on the M8 Serrated Flange Hex Nut should be perpendicular to the Beam. 25.12 Place (2) Mid-Clamp w/WEEB Assemblies on the Outer Beams, against the side of (2) Sunmodule Plus Solar Modules opposite the (2) End Clamp Assemblies. Place the (2) Module T-Bolts upside down into the groove and rotate the Module T-Bolts 90 degrees. Lift (2) Sunmodule Plus Solar Module slightly to fit (2) WEEBs underneath. 25.13 Repeat Steps 26.7-26.10 to secure the remaining inner Sunmodule Plus Solar Modules in the same portrait orientation. Secure the (2) Sunmodule Plus Solar Modules at the other end of the table with (2) End Clamp Assemblies, as explained in Step 25.2. QUALITY CHECK: Each table should have module end clamps at each end of the table's beams. (see photo).
NOTE: Quantity of Sunmodule Plus Solar Modules varies with Table Length. See Materials Box above and Table Lengths Description at beginning of manual. SolarWorld Sunfix Ground Mount Tilt Leg Version Installation Manual May 2013
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OBJECTIVE: To install and secure Sunmodule Plus Solar Modules to Tables.
Step 26: Secure all modules OBJECTIVE: To ensure safety and functionality of Sunmodule Plus Solar Modules and Tables 26.1 Once all table construction has been completed, secure all Modules on all Tables with final tightening. Follow Torque table for final tightening: Torque Table Torque Requirements
Nm
ft-lb
Flange Nut Serrated, M8, EC0496
20
15
Flange Nut, M10, SK5017
30
22
Hex Nut Serrated, M12, SA5229
28
21
CONGRATULATIONS! YOU HAVE SUCCESSFULLY INSTALLED THE SOLARWORLD SUNMODULE PLUS SOLAR MODULES ON THE SOLARWORLD SUNFIX GROUND MOUNT TILT LEG VERSION
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Production and sales locations of the SolarWorld group Location
Distributor
Rheinfelden
Freidberg
Bonn Grenoble
Madrid Boca Raton Hillsboro
SW-04-6090US 05-2013
Camarillo
Singapore
Cape Town
SolarWorld Ibérica, S.L. C/La Granja 15, Bloque B-1°B 28108 Alcobendas, Madrid Spain
SolarWorld France SAS Hôtel de l‘Entreprise, Petite Halle, Bouchayer-Viallet 31, rue Gustave Eiffel 38000 Grenoble France
SolarWorld Americas LLC 4650 Adohr Lane Camarillo, CA 93012 USA [email protected] solarworld.com
SolarWorld Africa Pty. Ltd. 20th Floor 1 Thibault Square Kapstadt, 8001 South Africa [email protected] solarworld-africa.co.za
SolarWorld AG Martin-Luther-King-Str. 24 53175 Bonn Germany Phone: +49 228 55920 0 Fax: +49 228 55920 99 [email protected] solarworld.de
SolarWorld Asia Pacific Pte. Ltd. 72 Bendemeer Road #07-01, Luzerne Singapore 339941 Singapore
solarworld.com
