Integra AVRii User manual

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1. List of components –Avrii INTEGRA Carport Structure-2 5
1.1. List of components - Avrii INTEGRA Carport Structure 4-10 6
2. List of tools necessary for assembly 7
3. Preparation for assembly 8
3.1. Preparation of assembly location 8
4. Selecting the mode of fixing to the ground 8
4.1. Poured foundation 8
5. Installing the vertical pillars 9
6. Fixing of the load-bearing structure for the PV modules 11
7. Fixing the cross battens 13
8. Installation of the PV modules 17
9. Expansion of the Avrii INTEGRA Carport Structure 4-10 20
CONTENTS LIST

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This manual was developed as a concise and user-friendly source of information on the safe installation in line with best
practices. We encourage you to make use of our support in the form of this manual, both before assembly as well as during
operation and inspections.
This document contains information concerning the construction, installation and safe use of the PV carport (referred to
in the manual simply as the ‘carport’).
Adhere to all EU and domestic provisions concerning the erection and usage of the load-bearing structure as well as the
electric equipment and systems.
Failure to adhere to the indications provided below can lead to death, bodily injury or property damage.
The installation specialist must read and understand the notes and information before installation. Any questions you may
have should be sent to our sales or technical departments. Before assembly, installation specialists should acquaint
themselves with the mechanical and electric requirements of the set.
The manual constitutes the fundamental source of information on rules concerning the handling, usage, execution of
installation and operation as well as the shut-down and disassembly of the relevant technical resources in terms of
cooperation with PV modules and electric vehicles.
Information provided in the manual is based on the following:
◼norms and provisions of the law as well as good engineering practices,
◼mechanical data and parameters of the components and devices,
◼data and electrical parameters of the components making up the electrical system,
◼knowledge of issues of PV structure robustness,
◼conducted analyses and inspections.
In case of discrepancies between the assembly manual and the manual attached to the assembly system or other
components of the PV system, immediately seek advice from Avrii specialists or entities authorised by Avrii to release
opinions concerning the installation and usage of their products. Following consultations and the acquisition of a technical
opinion from authorised entities, it is permitted to develop declarations concerning the modes of special use not covered
by the present manual.
The present manual should be stored in a safe manner, to be used in the future (operation and maintenance) as well as
in case of disassembly and resale.
We continuously work to improve our products and their documentation. For this reason, we recommend to always use
the latest version of the manual.
CONTACT DETAILS
Avrii Sp. z o.o.
VAT: PL 9930672075
ul. Mroźna 8A, 33-102 Tarnów, POLAND
◼www.avrii.eu
◼[email protected]
◼[phone] ext. 6
Introduction

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The adherence to general safety provisions at all times during installation and maintenance work as well as during
inspections guarantees the maintenance of system efficiency and reduces the risk of injuries and trauma.
◼Perform your work so as not to introduce greater risks than those that stem from the object of the work for yourself or
any potential bystanders.
◼Make use of assembly manuals attached to the relevant components.
◼Protect the construction/ installation area in a clearly visible manner, and mark it at a distance that is safe for
bystanders.
◼Use tools dedicated for the installation of PV systems by authorised manufacturers.
◼Have your delegation document to conduct work that you received from your superior at hand.
◼Have at their disposal the specific scope of competences related to your knowledge and qualifications.
◼Stay informed of the hazards that may be found at your work place.
◼At no time should unauthorised personnel be allowed to enter the construction/ installation area; by good practices,
technical culture and by law, it is absolutely forbidden to endanger bystanders, those not taking part in the assembly
◼Adhere to recommendations of you supervisors or assembly inspectors as they are decision-makers in terms of
technical solutions, for immediate introduction of potential improvements and changes with an indication of causes
and documentation of the reasons for changes
◼Keep at the construction site all certificates and documents confirming your licences as well as the operating
capacity of your equipment (helmets, safety harnesses, ladders, etc.) in order to show them during a possible
inspection by authorised supervisory bodies.
◼Avoid disadvantageous weather conditions, such as strong winds or precipitation
◼Do not work in snowfall or in the presence of ice.
This manual does not list all the precautions necessary for safe operation.
Safety resources
Installation specialists should adhere to OHS provisions and the relevant
recommendations:

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No.
Name
Technical drawning
Pcs.
1.
Structural support leg (vertical support post)
2
2.
End cap (steel)
2
3.
Hex screw
8
4.
Acorn nut
16
5.
Round spacer
16
6.
Profile B, 100 x 40 x 2, length 6000 mm
or shorter, suitable for the modules used
10
7.
Profile A, 160 x 80 x 5, length 5382 mm
2
8.
End cap 100x40 mm
20
9.
End cap 160x80 mm
4
10.
Threaded rod A2 M10X110
6
11.
Acorn nut A2 M10
12
12.
Round spacer A2 10,5 (M10)
12
13.
Bracket KAB_inox_3 mm
20
1. List of components –Avrii INTEGRA Carport Structure-2

6
14.
Hex screw M8X25 A2
40
15.
Clamp KPV_inox_1,5 mm
60
16.
Push screw M6X16 A2
60
17.
Seal 20x15 mm
36 m
No.
Name
Structure -4
Structure -6
Structure -8
Structure -10
1.
Number of spots
4
6
8
10
2.
Structural support leg
3
4
5
6
3.
Steel profile A 160x80x5x5382mm
3
4
5
6
4.
Steel profile B 100x40x2x6000mm
20
30
40
50
5.
Clamp KPV_inox_1,5mm
120
180
240
300
6.
End cap (steel)
3
4
5
6
7.
Hex screw M6x12 A2 (for end cap)
12
16
20
24
8.
Acorn nut A2 M20
24
32
40
48
9.
Round spacer A2 21 M20
24
32
40
48
10.
End cap 100x40mm
40
60
80
100
11.
End cap 160x80mm
6
8
10
12
12.
Threaded rod A2 M10X110
9
12
15
18
13.
Acorn nut A2 M10
18
24
30
36
1.1. List of components - Avrii INTEGRA Carport Structure 4-10

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14.
Round spacer A2 10,5 (M10)
18
24
30
36
15.
Bracket KAB_inox_3 mm
30
40
50
60
16.
Hex screw M8X25
60
80
100
120
17.
Push screw M6X16 A2
120
180
240
300
18.
Seal 20x15 mm –2 m x 18 pcs.
72
108
144
180
19.
B-profile connector
10
20
30
40
No.
Name
Pcs.
1.
Wrench 30 mm
1
2.
Wrench 17 mm
2
3.
8 m tape measure
1
4.
Rubber hammer
1
5.
Articulated ladder –height: 3 m
2
6.
Hex key, 3, 4, 6 mm
2
7.
Transport belt/sling
1
8.
PPE
2
2.List of tools necessary for assembly

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In order to assess the location of erection of the system outside of geometric components, and for spatial orientation,
analyse this list of additional components influencing the ultimate assessment, such as:
◼Inclination Azimuth
◼Presence of trees, pillars and other tall objects
◼Distance to other buildings
◼Distance to hazard and danger zones
The place of installation should be even, it may have a slight inclination of up to 5% against ground level. All concrete
components should be level so as not to cause shifts against the soil and ensure structure stability.
At the selected spot, following precise measurements and an inspection of diagonals, prepare an excavation and fit your
formwork. The foundation slab should be made of at least B25 concrete with steel rebar of ribbed rods, min. diameter
10 mm. Crosswise reinforcement of rods, at least 6 mm.
The rebar should be installed horizontally. To the upper rebar portion, tie (using tie wire) or weld the anchor and rebar
components of the car port (threaded rods).
The horizontal heights of both foundation pieces and their distribution against each other should be the same so that the
vertical support posts are placed symmetrically against each other. The upper portion of the foundation should be levelled
precisely.
As an alternative, use ready steel patterns or drill openings in the concrete and use chemical anchors.
3. Preparation for assembly
3.1. Preparation of assembly location
4. Selecting the mode of fixing to the ground
4.1. Poured foundation
We are attaching a diagram of the ordered carport,
as dimensions may vary due to the utilised PV modules and
the width of the available parking spot.

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All work should be carried out by at least two people
The vertical posts are fixed to the threaded M20 rods protruding from the foundation. The posts should be directed towards
the entry direction (see fig. 1), and the caps should be found on the inner side of the carport.
Fig. 1. Mode of installation of the vertical support posts.
First of all, remove all contaminants from the upper portion of the foundation and the threaded rods. Put the support post
onto a foundation prepared in this manner, and fix it with acorn nuts with M20 spacers.
The tightening moment of the screws should be ca. 30-50 Nm.
5. Installing the vertical pillars

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The transport, set-up and installation
of the vertical support posts on the
foundation should be performed with
the aid of a forklift truck.
Fix the mounting screws precisely in
the fixing openings of the vertical
support post.
Using the M20 acorn nuts with
spacers, fix the post to the foundation
base.
The bolt tightening moment should be
ca. 100 Nm.
1.
2.
3.

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Before commencing with the assembly, check the spacing of the support posts against each other, and confirm that the
support posts are fixed in a vertical position.
In case of divergences from the vertical, perform the necessary corrections using spacers for the fixing bolts.
Then insert the steel profile A (160 x 80 x 5) into the recess in the support post and fix with three M10 x 110 fixing screws and
acorn nuts, using spacers on both sides.
Fig. 2. Mode of fixing of profile A to the support post.
The profiles must be arranged in such a way so that the assembly openings overlay with the assembly openings of the
support posts.
In order to avoid cracks on the
surfaces of the components to be
joined, protective film can be used.
6. Fixing of the load-bearing structure for the PV modules
4.

12
Prepare the joining location of the two
components in such a way so that the
assembly openings overlay with the
assembly openings of the support
post.
Put the M10 spacer on the M10
threaded rod, affix the nut.
Pull the rod through the openings.
Then attach the spacer and tighten
the bolt using the wrench.
5.
6.
7.

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Tighten the bolts with a mean
moment of 20-30 Nm.
Correctly executed mounting of profile
A with the support post.
Special fixing units allow quick fastening of B profiles (100 x 40 x 2 mm) to A profiles (160 x 80 x 5 mm).
Fig. 3. Profile B (100 x 40 x 2 mm)
Profile B is fixed directly to profile A using stainless steel grips and M8x25 hex screws.
7a.
7b.
7. Fixing the cross battens

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Fig. 4. Mode of fixing of profile B to profile A
Profile B is fixed at recesses in profile A.
Profile B is fixed symmetrically against
vertical support posts.
8.
9.

15
Then, fix the B profiles to the A profiles
using the grips and M8 bolts included
with the delivery.
Check the required support points for
the utilised modules in the assembly
manual of the PV module
manufacturer.
The attached profiles shall form the structural matrix, to which the modules will be fixed.
Fig. 5. Structural matrix made of A and B profiles.
10.
10a.

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Then fix the end caps on the profiles.
A structure prepared in this manner is
ready for the installation of PV
modules and other components.
Correctly installed Structure-2 of the
Avrii INTEGRA carport.
11.
12.
13.

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The structure is designed for wind zone one and Snow Zone II - profile B 100x40x2x5382mm, Snow Zone III - profile B
100x40x4x5382 mm.
Should the paint coat be damaged during installation, each set is provided with a can of paint of the same colour as the
applied coat in order to mask or paint over the damaged surfaces.
The modules are fixed by way of specially-designed clamps. The fixing entails gripping the base of the module frame and
the B profile 100 x 40 x 2 mm using the clamp, and then tightening the M6x16 A2 screw. The torque should be 15 to 20 Nm.
Fig. 6. Clamp KPV_inox_1.5 mm
Installing the seal. Before we
commence attaching the modules, fix
the seal to the longer side of the car
port, designed to ensure water
tightness.
8. Installation of the PV modules
Fixing the PV modules
14.

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Trim the seal so that it protrudes 2-3
mm outside of the module frame on
both sides.
After fixing the first row of modules, fix
the seal along their shorter sides,
along the entire length, so that the
joints of the seal do not overlap with
the spaces between modules.
1.
2.
3.
Fig. 7. Mode of correct installation of seals on the PV modules.
1 –fixing the seal to the longer module side
2 –fixing the modules with seals to the structure
3 –fixing the seal across the entire length, along the shorter sides of the modules.
15.
16.

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The grips fixing modules to the profiles
should be mounted from the
underside, shifting the cut-out in the
grip on the frame base. Then tighten
the bolt. The torque should be ca. 15-
20 Nm.
A structure prepared in this manner is
ready for the installation of PV
modules and other components.
Establish electrical connections
between the modules, and then cover
the openings with the steep end cap
included in the set
17.
17a.
18.

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It is possible to expand the Avrii INTEGRA Carport Structure-2 by additional parking spots using expansion systems.
Expansion systems require the selection of B profile length according to the utilised PV modules and the width of the
parking spots. The joints between B profiles will use joint components attached to every Avrii INTEGRA Carport Structure-2
expansion order.
Fig. 8. Mode of joining of B profiles to expand the carport structure
9. Expansion of the Structure 4-10
carport
Joining of B profiles