INSTALLATION MANUAL TERRAFARM SOLAR RACKING SYSTEM FOR TerraFarm Features

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