DPA Solar - Ground Mount Installation Guide V1.5
DPA Solar Racking Solutions
Ground Mount Installation Guide V1.5
Ground Mount Installation Guide
Introduction It is important to note that the installer is responsible for the following: •
Complying with all applicable local or national building codes, including any that may supersede this manual;
•
Complying with all electrical, health and safety and other applicable regulations as applicable to the location;
•
Ensuring that DPA Solar racking and other products are appropriate for the particular installation and the installation environment;
•
Ensuring that foundations, piles, footings and associated securing / attachment are sufficient for the geographic location, applicable wind load and soil types;
•
Fitting galvanic isolation where required to protect against dissimilar metals corrosion; and
•
Ensuring safe installation of all electrical aspects of the PV array.
This product is Warranted to be free from defective material and workmanship for a period of 10 years. Please visit www.dpasolar.com.au/support for full warranty details. The nature and type of the footings / foundations, and the attachment to them is the responsibility of the installer, taking into account local conditions and geography, soil types, wind loads applicable to the area and local planning considerations.
Page 2 of 6 Please download the latest version of this document from www.dpasolar.com.au prior to commencing installation. Under no circumstances shall DPA Solar be liable for special, indirect or consequential damages arising out of use of this product.
V1.5
Ground Mount Installation Guide
V1.5
Components Item
Part Number
Rail
DR2-R-2100 DR2-R-3405 Solar Rail 2100mm / 3405mm
Splice
DR2-R-SP Splice
Rear Leg
DR-GM-RL Rear leg 60 x 1990mm (inc. 2 x U-bolt)
Front Leg
DR-GM-FL Front leg 60 X 985mm (inc. 2 x U-bolt)
Cross Pipe
DR-GM-CP-3200 Cross pipe 60 x 3200mm DR-GM-CP-4800 Cross pipe 60 x 4800mm
Angle Iron
DR-G-EP Re-enforcing pipe 1850mm (inc. 2 x nut/bolt)
Supporting Pipe Splice
DR-GM-SK Angle splice kit (inc. 1 x U-bolt)
End Clamp
DR2-EC-XX End clamp (XX = profile)
Mid Clamp
DR2-IC-XX Mid clamp (XX = profile)
Ground Screw
DR-N76-1600-T4 1600mm x 74mm x 4mm wall
Ground Screw Flange Adapter
DR-N76-GSC01
Page 3 of 6 Please download the latest version of this document from www.dpasolar.com.au prior to commencing installation. Under no circumstances shall DPA Solar be liable for special, indirect or consequential damages arising out of use of this product.
Ground Mount Installation Guide
V1.5
Planning The two main methods to mount the array are using concrete footings or using screw piles (DRN76-1600-T4). Expanding type bolts (dyna bolts), chemically embedded bolts (chemsets) and pre-installed bolts / threads can be used into concrete. Concrete can be laid as a pad, strip footings or individual piles. Depending upon the nature of the footings and attachment to the footings, it may be desirable to assemble the system prior to permanently installing any foundation bolts or drilling any holes for fasteners. The system can be assembled free standing in order to fully confirm required dimensions. There are 2 main dimensions that need to be calculated in order to install the system – distance from front to rear legs (A) and distance between left and right legs (B). Refer to the diagrams at the bottom of the page. The height of the front and rear legs can be adjusted to a small degree to suit the gradient of the site, particularly if screw piles or individual footings are used. The resulting value ‘A’ is the spacing between front a rear legs. ‘A’ is nominally 1700mm, however if the front and rear legs are not at the same level then ‘A’ will vary.
Strip footings
Individual footings
Screw piles
The distance between the left and right sets of legs is set by the cross pipe length. ‘B’ is nominally the Cross Pipe length less 200mm = 3000mm or 4600mm. Some adjustment is possible – refer to the following pages for assembly instructions.
Page 4 of 6 Please download the latest version of this document from www.dpasolar.com.au prior to commencing installation. Under no circumstances shall DPA Solar be liable for special, indirect or consequential damages arising out of use of this product.
Ground Mount Installation Guide
Installation Steps 1
Attach front and rear legs to footings / foundations using the selected fixing method.
2
Fit angle iron between the base of the rear leg and the top of the front leg. Note that the right-angle needs to face away from the tag / cleat on each leg.
3
Fit the cross pipes to the front and rear legs using Ubolts. Align the plate on each leg flush with the cross pipe end, or move the leg in from the end so that it is centered up to 100mm from the cross pipe end. Variations due to galvanising around the holes in each leg plate and the tendency of Ubolts to spring open over time, may result in some Ubolts requiring mechanical assistance to be fitted.
4
Fit the supporting pipe splices to the rails, then fit to the front and rear pipes. Note that it is easiest to fit the splice to the rail, then the rail / splice assembly to the pipe (not the other way around). Space the rails so that each rail sits approximately 15% in from the panel end.
Page 5 of 6 Please download the latest version of this document from www.dpasolar.com.au prior to commencing installation. Under no circumstances shall DPA Solar be liable for special, indirect or consequential damages arising out of use of this product.
V1.5
Ground Mount Installation Guide
5
V1.5
Fit the panels using end clamps and mid clamps as shown. Adjust the rail height for each rail using the slots in the supporting rail splices to level the panels. Tighten all clamps to approximately 15 Nm. Cut off any excess rail.
Illustration of completed 8 panel monocrystalline installation
Page 6 of 6 Please download the latest version of this document from www.dpasolar.com.au prior to commencing installation. Under no circumstances shall DPA Solar be liable for special, indirect or consequential damages arising out of use of this product.
Ground Mount Installation Guide V1.5
Ground Mount Installation Guide
Introduction It is important to note that the installer is responsible for the following: •
Complying with all applicable local or national building codes, including any that may supersede this manual;
•
Complying with all electrical, health and safety and other applicable regulations as applicable to the location;
•
Ensuring that DPA Solar racking and other products are appropriate for the particular installation and the installation environment;
•
Ensuring that foundations, piles, footings and associated securing / attachment are sufficient for the geographic location, applicable wind load and soil types;
•
Fitting galvanic isolation where required to protect against dissimilar metals corrosion; and
•
Ensuring safe installation of all electrical aspects of the PV array.
This product is Warranted to be free from defective material and workmanship for a period of 10 years. Please visit www.dpasolar.com.au/support for full warranty details. The nature and type of the footings / foundations, and the attachment to them is the responsibility of the installer, taking into account local conditions and geography, soil types, wind loads applicable to the area and local planning considerations.
Page 2 of 6 Please download the latest version of this document from www.dpasolar.com.au prior to commencing installation. Under no circumstances shall DPA Solar be liable for special, indirect or consequential damages arising out of use of this product.
V1.5
Ground Mount Installation Guide
V1.5
Components Item
Part Number
Rail
DR2-R-2100 DR2-R-3405 Solar Rail 2100mm / 3405mm
Splice
DR2-R-SP Splice
Rear Leg
DR-GM-RL Rear leg 60 x 1990mm (inc. 2 x U-bolt)
Front Leg
DR-GM-FL Front leg 60 X 985mm (inc. 2 x U-bolt)
Cross Pipe
DR-GM-CP-3200 Cross pipe 60 x 3200mm DR-GM-CP-4800 Cross pipe 60 x 4800mm
Angle Iron
DR-G-EP Re-enforcing pipe 1850mm (inc. 2 x nut/bolt)
Supporting Pipe Splice
DR-GM-SK Angle splice kit (inc. 1 x U-bolt)
End Clamp
DR2-EC-XX End clamp (XX = profile)
Mid Clamp
DR2-IC-XX Mid clamp (XX = profile)
Ground Screw
DR-N76-1600-T4 1600mm x 74mm x 4mm wall
Ground Screw Flange Adapter
DR-N76-GSC01
Page 3 of 6 Please download the latest version of this document from www.dpasolar.com.au prior to commencing installation. Under no circumstances shall DPA Solar be liable for special, indirect or consequential damages arising out of use of this product.
Ground Mount Installation Guide
V1.5
Planning The two main methods to mount the array are using concrete footings or using screw piles (DRN76-1600-T4). Expanding type bolts (dyna bolts), chemically embedded bolts (chemsets) and pre-installed bolts / threads can be used into concrete. Concrete can be laid as a pad, strip footings or individual piles. Depending upon the nature of the footings and attachment to the footings, it may be desirable to assemble the system prior to permanently installing any foundation bolts or drilling any holes for fasteners. The system can be assembled free standing in order to fully confirm required dimensions. There are 2 main dimensions that need to be calculated in order to install the system – distance from front to rear legs (A) and distance between left and right legs (B). Refer to the diagrams at the bottom of the page. The height of the front and rear legs can be adjusted to a small degree to suit the gradient of the site, particularly if screw piles or individual footings are used. The resulting value ‘A’ is the spacing between front a rear legs. ‘A’ is nominally 1700mm, however if the front and rear legs are not at the same level then ‘A’ will vary.
Strip footings
Individual footings
Screw piles
The distance between the left and right sets of legs is set by the cross pipe length. ‘B’ is nominally the Cross Pipe length less 200mm = 3000mm or 4600mm. Some adjustment is possible – refer to the following pages for assembly instructions.
Page 4 of 6 Please download the latest version of this document from www.dpasolar.com.au prior to commencing installation. Under no circumstances shall DPA Solar be liable for special, indirect or consequential damages arising out of use of this product.
Ground Mount Installation Guide
Installation Steps 1
Attach front and rear legs to footings / foundations using the selected fixing method.
2
Fit angle iron between the base of the rear leg and the top of the front leg. Note that the right-angle needs to face away from the tag / cleat on each leg.
3
Fit the cross pipes to the front and rear legs using Ubolts. Align the plate on each leg flush with the cross pipe end, or move the leg in from the end so that it is centered up to 100mm from the cross pipe end. Variations due to galvanising around the holes in each leg plate and the tendency of Ubolts to spring open over time, may result in some Ubolts requiring mechanical assistance to be fitted.
4
Fit the supporting pipe splices to the rails, then fit to the front and rear pipes. Note that it is easiest to fit the splice to the rail, then the rail / splice assembly to the pipe (not the other way around). Space the rails so that each rail sits approximately 15% in from the panel end.
Page 5 of 6 Please download the latest version of this document from www.dpasolar.com.au prior to commencing installation. Under no circumstances shall DPA Solar be liable for special, indirect or consequential damages arising out of use of this product.
V1.5
Ground Mount Installation Guide
5
V1.5
Fit the panels using end clamps and mid clamps as shown. Adjust the rail height for each rail using the slots in the supporting rail splices to level the panels. Tighten all clamps to approximately 15 Nm. Cut off any excess rail.
Illustration of completed 8 panel monocrystalline installation
Page 6 of 6 Please download the latest version of this document from www.dpasolar.com.au prior to commencing installation. Under no circumstances shall DPA Solar be liable for special, indirect or consequential damages arising out of use of this product.
