Chiko CK-ZEM User manual

CK-ZEM | STEEL SOLAR CARPORT | GAZEBO
STEEL SOLAR CARPORT | GAZEBO
INSTALLATION MANUAL
VERSION: 0623V01 | ENG

BRIEF DESCRIPTION
MAINTENANCE
Always use the most recent version of the installation manual before installing your Carport/Gazebo.
The installation Manual is subject to change without notice. Please consult with CHIKOUSA to ensure
you are utilizing the latest Install Manual.
WARNING
If any structural component of the system to include the column, beam, base plate, or rail are
damaged they must be replaced immediately.
CK-ZEM Steel Solar Carport/Gazebo is a robust double carport that can accommodate 3 panels in
portrait, 6 across, totaling 18 panels. This structure can be installed with a 2-3 person crew, without
the Need of any heavy duty tools. The installation should always be completed by trained
professionals and/or qualied individuals, who have been adequately instructed and trained about
the tasks involved with the installation, including the usage of protective devices, protective
measures, relevant provisions, accident prevention regulations, and local operating site conditions
and have proven competence in all areas of the installation.
Please read carefully this installation manual and all other applicable documents before starting your
installation. Please contact CHIKO with any questions that you may have.
When signs of rust appear, or when the paint is peeled or removed, you must take steps to
remove the rust and paint the aected areas.
1.
You must check the bolts are secured once a year. Tighten according to torque specs.2.
If the columns of the structure are hit, you must replace the columns of the structure immediately.3.
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REQUIRED TOOLS
MAIN COMPONENTS
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GLOVES INK FOUNTAIN TAPE MEASUREWRENCH
END-CLAMP WATER CHANNEL WATER-PROOF RUBBERMID-CLAMP
Customer needs to source materials for footings based on structural engineer specications.
NOTE
M RAIL PURLIN FIXED KIT BASE PLATE
SELF-TAPING SCREW BEAM ADAPTER STRENGTH ADAPTER
HARDHAT SAFETY GLASSES

MAIN COMPONENTS
Overview/Diagram
The following is a diagram that list the mian components of the
CK-ZEM Carport SYstem
1Support Rack 1
1.1 Front Column 2
1.2 Rear Column 2
1.3 Support Beam 2
1.4 Legs Strengther Beam 1
2C Rail Fix Kit 10
3C Rail - 7300 5
4M Rail - 5760 7
5End Clamp 12
No Description QTY
6End Clamp share plate 12
7Mid Clamp 30
8Mid Clamp share plate 30
9Column Bracing-5410 1
10 Column Bracing Fix Kit 2
11 Water Channel-1061 12
12 Waterproof Rubber-1133 12
13 M6.3*25 70
14 M6.3*16 42
No Description QTY
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CAT CAT
1
1
1
1
1
4
4
2
5
5
5
5
1
1
2
2
3
3

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FRONT VIEW LEFT VIEW
TOP VIEW

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COMPONENTS LIST
CAT Picture Description PART# Details QTY
1
2
Carport
M Rail
3
Water Channel
Front Columns1.1 2
Rear Columns1.2 2
M Water-proof Rail2.1 6
Self Taping Screw2.2 60
Water Channel
3 10
3
Water
Proof Strip
Water Proof Rubber
310
Base Plate1.3 4
Beam1.4 2
Beam Adapter1.5 4
Strengthen Beam 11.6 2
Strengthen Beam 21.7 1
Strengthen Adapter1.8 6
HDG Bolt M12*1401.9 20
HDG Bolt M14*1551.10 30
HDG Nut M121.11 20
HDG Nut M141.12 30
HDG Washer M121.13 40
HDG Washer M141.14 58
HDG Spring Washer M121.15 20
HDG Spring Washer M141.16 30
4 Purlin 45
CK-
ZEM-010-5760
CK-ZEM-009-1062
CK-IP-160-1133
C CHANNEL
Purlin 'C' Channel
CK-PL-
C140-001-016-811-600 0
CTI
SECT.
1, 2,3,
8
9
9
6
Support
4,5
Structure
CK-ZEM-CP3-5
COLUMNS
CK-001-016-014
BEAMS
CK-
GT-001-016-014
Base 'Plate'CK-
GT-001-016-805
Column/Beam
Adapters
Beam
CK-GT-001-016-014
Column
CK-001-016-014

CAT Picture Description Part# Details QTY
4
Purlin Fix Kit
5
Purlin Fix Kit4.110
HDG Bolt M10*404.2 40
HDG Bolt M12*1404.3 20
HDG Nut M104.440
HDG Nut M124.5 20
HDG Washer M104.680
35mm Mid Clamp5.1 24
845 Share Plate5.2 24
M Grounding Plate5.3 24
Self Taping Screw5.4 48
SS304 Bolt M8*455.5 24
SS304 Spring Washer M85.6 24
HDG Washer M124.740
HDG Spring Washer M104.8 40
HDG Spring Washer M124.9 20
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5
End Clamp 35mm End Clamp
5.7 12
845 Share Plate
5.8 12
M Grounding Plate
5.9 12
Self Taping Screw
5.10 24
SS304 Bolt M8*45
5.11 12
SS304 Spring Washer M8
5.12 12
CK-PL-
GT001-016-14
Mid Clamp
CK-782-4-60-Q
CK-737-3-60-Q
6
Grounding Lug
CK-GTC-R2
6.1
6.2
1
1
1
Grounding lug - weeb lug 8.0
SS304 outer hex bolt 1/4"
*0.6”
SS304 inner hex bolt M8*20
86.3
.3 1
SS304 inner hex bolt M8*20
1
SS304 inner hex bolt M8*20
86.4 1
SS304 inner hex bolt M8*20
C RAIL
SECT
N
6
8,
9
8,
9
10
BRACKET #
#CK-A845-801
BRACKET #
#CK-A845-801

INSTALLATION STEPS
1. Build Base
Solution A, Build base
Mark footer location according to the diagram. Verify all angles are square.
Solution B, Concrete anchors
Concrete anchors can be utilized if approved by a structural engineer.
Dig footers and make base with anchor bolts according to site conditions and system
specications and based on your structural engineer instructions for foundations requirements.
If the ground is unlevel, ensure that all footer placements are level and at the same height
regardless of the terrain elevation. Never install the structure tilted, the columns must
always be straight.
In areas subject to freezing, footer depths may have to increase to resist freeze heave.
Always consult a structural engineer to conrm footer depth and dimension.
The structure's foundations should be calculated taking into account site conditions, soil type,
seismic conditions, maximum wind and snow loads for the site location and the product
mechanical loading specications. In some cases, a geotechnical study is required.
Please consult with your local structural engineer.
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2. Install Base Plates
Slide the column base plate over the concrete anchors and secure them. If you are using leveling
nuts to level the column base plate. Correct any shifting if needed and repeat for the other three
column base plates. Fill the gap between the base plate and the footing with
Dry-pack non-shrink grout.
Tip: The distance between the front and rear column conform with drawing.
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Products Name Quantity
Base 4
M12 Nut Kits (1 flat washer + 1 spring washer + 1 nut) 4

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3. Fix Adapter
A . Fix strengthen adapters on front & rear columns
B1. Fix beam adapters on main beam - 5400mm
Products Name Quantity
Strengthen Adapter 6
M12*140mm Bolt Kits (1 big flat washer + 1spring washer + 1 nut)
Beam Adapter
Purlin Fix Kit
30
4
10
B2. Fix purlin x kit to main beam - 5400mm
A
B1 & B2

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4. Connect Columns
Attach Columns to base plate-if concrete anchors, use corresponding Anchor Bolts
Products Name Quantity
Front Columns --- 2770mm 2
Rear Clolumns --- 3128mm
M10*120mm Bolt Kits (1 flat washer + 1 spring washer + 1 nut)
2
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5. Connect Beams
Connect beam 3910mm between front and rear columns
Connect beam 5410mm between 2 rear columns
Products Name Quantity
Main Beam --- 5400mm 2
Beam ---- 3910mm
Beam ---- 5410mm
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M12*140mm Bolt Kits (1 flat washer + 1 spring washer + 1 nut)
55
44
11
00
5
4
0
0
5
4
0
0
3
9
1
0
1
3
2
2
1
20
Connect main beam 5400 mm between front and rear columns on top

6. Fix C Rail
Use purlin x kit to connect C rail 5745mm to main beam 5400mm
Use M10*40mm Bolt Kits (1 at washer + 1 spring washer + 1 nut) Connect to C Rail
Products Name Quantity
C Rail --- 5745mm 5
L Fix kit --
M10*40mm Bolt Kits (1 flat washer + 1 spring washer + 1 nut)
M12*140mm Bolt Kits (1 flat washer + 1 spring washer + 1 nut)
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10
20
10
Use M12*140mm Bolt Kits (1 at washer + 1 spring washer + 1 nut) Connect to main beam

L1L2L3L3
L2L2L4
7. Pre-assemble clamps on M Rail
Pre-x share plate to M rail
Connect mid clamps to share plate
Products Name Quantity
M Rails—5760mm 6
Share Plates
Mid Clamps
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M6.3*16
36
24
End Clamps 12
72
Please check L1/L2/L3/L4 before xing
TIP: Place 2 M-Rails in parallel on a at level surface, then lay 3 panels in portrait on top of
The M-Rails, ensuring proper spacing, then mark your share plate locations. Use these
Measurements to install the remaining share plates on the remaining M-Rails.
For Mid Clamp and End Clam Installation: M8 Torque: 15~20N.m

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8. Fix M Rail
Use M6.3*25 self tapping screw to x M rail to C Rail
With end clamps on the side M Rails
With mid clamps on the inner M Rails
L
L
L
L
L
L
Products Name Quantity
M Rails 6
M6.3*16 72
TIP: This is a critical step; if possible lay 7qty M-Rails down on at level surface; place 6
panels across these M-Rails in Portrait conguration, ensure rails and panels are square;
take measurement to conrm your starting M-Rail attachment location.
Please check the L measurement before attaching

9. Install Solar Panels
For waterproong stick rubber molding to exterior of module frame but only where the frames are
adjacent to other module frames or on all interior seams
Install water channel (1061mm) where 2 panels meet under the module frame
Products Name Quantity
Modules 18
Rubber
Water channel -- 1061
12
12
2
1 3
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60.162 4.1148 0.3951 1.295928 37 1100 Hz
70.1443 3.66522 0.4982 1.634096 30 1300 Hz
80.1285 3.2639 0.6282 2.060496 24 1650 Hz
90.1144 2.90576 0.7921 2.598088 19 2050 Hz
10 0.1019 2.58826 0.9989 3.276392 15 2600 Hz
AWG Diameter
[inches]
Diameter
[mm]
Resistance
[Ohm / 1000ft.]
Resistance
[Ohm / km]
Max Current
[Amperes]
Max Frequency
for 100% skin depth
Electrical Characteristics of AWG Copper Wire
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10. Grounding- Lug and Wiring
0,'&ODPSDWWDFKHGWRHYHU\PRGXOHSURYLGHPRGXOHWRPRGXOHERQGLQJ(END at either end of row). Install
groundinglugatendofC-Railinpre-drilledhole,ensurethatallpaintandanydebrisisremovedfrombonding
sitetoachievebondingconnection.Attachthegroundlugwithastainlesssteel,nutthencross8.4mm2or
greaterthanorequalto8AWGcopperwirethroughall5groundinglugs(xedbyM8*20innerhexbolt),nally
connectcopperwiretotheground.Thegroundinglugcompletesagroundingfunctionwhenfastenedtight
toconnectall5CRailsandcopperwire. Then run copper wire, attached to the column, and down into the
ground, attaching to ground rod or other ground.

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Grounding – Lug and Wiring Diagram
Grounded End Clamp Grounded Mid Clamp Ground Path Grounding Lug
#8 AWG or Greater
MID Clamp attached to every module provide module to module bonding

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11. Final Check
Check all bolts are fastened, all components are in right position
Check and adjust the entire structure
12. Hide Footing (Optional- not applicable if Concrete Anchor)
Cement cladding for 4 bases,Cladding Size: 300mm*300mm*300mm.
Cement grade: not less than C30.

LO LEADING
M A N u F A
 
 
RACKING MADE SIMPLE
C T U R E
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
 
 
 