s-rack Sigma S1 User manual

Sigma S1
Installation Manual

Sigma S1 Installation Manual
Contents:
1
Introduction
1.1
Description
1
1.2
About the Manual
1
1.3
Warnings
2
1.4
Safety
2
2
Technical Description
2.1
System Overview
3
2.2
Component Details
4
2.3
Module Clamps
5
3
Project Drawing and Bill of Materials
6
4
Basic Installation Requirements
4.1
System Units
6
4.2
Required Tools
6
4.3
Tightening Torques
6
5
Foundation
7
6
Support Assembly
8
7
Purlin Installation
9
7.1
Purlin Placing and Alignment
9
7.2
Purlin Connector
9
8
Module Clamp Installation
10
9
Module Installation
9.1
Framed Modules –Portrait
11
9.2
Framed Modules –Landscape
12
9.3
Frameless Modules –Portrait
13
9.4
Frameless Modules –Landscape
13
10
Maintenance
10.1
Inspection
14
10.2
Testing
14

1Sigma S1 Installation Manual
Sigma S1 Installation Manual
1. Introduction
1.1. Description
The Sigma S1 is a single post PV ground mount system
that allows for flexible arrangement of modules in either
portrait or landscape orientation and can be installed by
means of driven piles.
1.2. About the Manual
Content
These instructions provide important information
regarding system, components, planning and safety
warnings when handling the Sigma S1.
Sections 1, 2 and 3 show an overview as well as detailed
information about the Sigma S1 and its components.
Section 4 provides the basic planning information. The
remaining sections provide detailed system assembly and
installation instructions.
Installation Manual Validity
This installation manual is only valid in conjunction with:
•S-Rack Australia Pty Ltd’s Terms and Conditions. This
document applies to all contracts and agreements
for all products and services offered by S-Rack
Australia Pty Ltd.
•The Project Specific Drawings. These documents
show all the project specific installation details,
choice of components, dimensions and any
deviation from the standard material/assembly.
Therefore, these drawings take precedence over the
installation manual in case of discrepancies between
the two documents.
•The supplied material for the Sigma S1 according to
the Bill of Materials (BOM).
The content of these documents must be followed during
installation for the S-Rack Australia Pty Ltd warranty to
apply.
Please read and check the Installation Manual, Project
Drawings and Bill of Materials carefully prior to any
installation, maintenance, and disassembly work.
All necessary information regarding installation,
maintenance and disassembly will be provided. If you
have any questions after having read these documents,
please contact S-Rack Australia Pty Ltd.
Target Group
Skilled and trained personnel.
Skilled/Trained Personnel
An individual who has acquired professional training and
as such, capable of executing installation, maintenance
and disassembly work properly.
Guidance Notes
Please see below installation guidance notes.
Symbols:
Important information and useful tips
Additional information and hints to make
the installation process easier

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Sigma S1 Installation Manual
1.3. Warnings
The following are used in the installation manual to
indicate safety-related information. These include:
•Warning Symbols
•Signal words which identify the hazard level
•Information about the type and source of the hazard
•Information about the potential consequences if the
hazard is disregarded
•Measures to prevent injuries and damage to
property
The signal words of the warnings respectively indicate
one of the following hazard levels:
DANGER
Indicates a potentially fatal danger
which may result in death or serious
injury if ignored.
WARNING
Indicates a potentially dangerous
situation which may result in serious
injury or damage to property if
ignored.
CAUTION
Indicates a potentially dangerous
situation which may result in injuries
or damage to property if ignored.
ATTENTION
Indicates potential danger which can
result in damage to property if
ignored
1.4. Safety
Safety instructions for S-Rack Australia Pty Ltd products
are included in the documents. Do not use the products
in a manner other than its intended function.
It is the responsibility of the customer to ensure that all
general and specific safety instructions are followed.
In addition, please observe the specific safety instructions
provided in this Installation Manual for all installation
work. The specific safety instructions are positioned in
each case directly with the respective installation steps.

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Sigma S1 Installation Manual
2. Technical Description
This section provides a breakdown of the Sigma S1 and its components. Upon delivery of the system, check to ensure
that all parts and components adhere to the BOM and project specific drawings. Any items missing or damaged must
be notified to S-Rack Australia Pty Ltd immediately.
2.1. System Overview
An overview of the Sigma S1 system can be seen below (Image 2.1-1). Please note that some components can vary
depending on project-specific requirements.
Image 2.1-1 - System Overview of the Sigma S1 System
Driven Pile
Girder
Strut
Purlin Clamps
Module Clamps
Purlin

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Sigma S1 Installation Manual
2.2. Component Details
Overview of System Components
Foundation
Girder
Strut
Purlin
Purlin Connector
Purlin Clamp with Cage Nut

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Sigma S1 Installation Manual
2.3. Module Clamps
Module Clamps are used to secure the PV modules
to the Sigma S1 purlins. Module clamps are
equipped with a clickstone, while laminate clamps
use a T-head bolt to install the module clamps into
the Sigma S1 purlins.
Module End Clamp
These clamps are installed at the start and end of a
PV module row. These clamps are available in
discrete sizes allowing it to precisely match the
required PV module thickness.
Module Mid Clamp
These clamps are installed in-between PV modules
along a PV module row and can be integrated with
grounding pins.
Laminate Mid/End Clamps
Laminate module clamps allow frameless modules
to be mounted without applying too much pressure
on the modules.
Image 2.3 –2 Module End Clamp
Image 2.3 –1 Module Clamps
Image 2.3 –3 Module Mid Clamp with Grounding Pins
Image 2.3 –4 Laminate Mid Clamp
Image 2.3 –5 Laminate End Clamp

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Sigma S1 Installation Manual
3. Project Drawings and Bill of Materials
Project-specific documentation is supplied as part
of the Sigma S1. These documents contain all the
information necessary to install the system.
The documentation includes:
•Bill of Materials
•Project Drawings (s) which show:
oExact module configuration for
the project
oSpecific foundation information
for the project
oDimensions and tolerances
4. Basic Installation Requirements
4.1. System Units
The Sigma S1 is designed in separate system units
which can be up to 30m long (without expansion
gaps). Please refer to the BOM and Project
Drawings for the dimensions of a specific system
unit.
4.2. Required Tools
In order to mount the Sigma S1, the following tools
are required:
•Power drill/electric screwdriver
•Folding rule/measuring tape
•Angle measuring tool (protractor)
•Spirit level or laser level tool
•M6 Allen key for module clamps
•M8 Allen key for laminate module clamps
•Wrenches for M10 and M12 bolts
4.3. Tightening Torques
A good quality torque wrench should be used to
tighten bolted connections to the torque
requirements below.
Connection
Size
Nm
Piles, girder, and struts
M12
40
Purlin clamps and cage nut
M10
30
Laminate module clamps
M8
15
Module clamps
M6
10

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Sigma S1 Installation Manual
5. Foundation
Driven piles should be oriented as shown in Image 5.1 -1. Make sure that the posts are positioned and installed within
the tolerances. The corresponding tolerances will be specified in the project drawings.
Note:
As an alternative to ramming, piles can also be encased in concrete / stabilised sand.
Refer to project documentations for specific dimensions and requirements.
Tolerances
Image 5.1 –1 Orientation of Driven Piles
In the absence of specific information in the drawings, the following guidelines apply:
1. Post height max. ± 2 cm based on planned height
2. Position E-W max. ± 5 cm, Position N-S max. ± 2 cm
3. Inclination tolerance E-W max. 2° (1° ≈ 2cm/m)
4. Inclination tolerance N-S max. 2°
5. Torsion max. 2°
6. Axis tolerance E-W max. ± 2cm based on the post top
Hint!
After the ramming posts have been set, the pile head (about 3cm) should be treated with a zinc dust primer.
This prevents premature corrosion and thus support the longevity of the system.

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Sigma S1 Installation Manual
6. Support Assembly
Installation Steps
Connect the girder (pre-assembled with purlin clamps), strut (pre-assembled) and pile together as shown in (Image
6.1). Please refer to the Project Drawings and BOM for the correct type, positioning and small parts used for the
connections. Make sure to observe the right tightening torques.
Note:
Depending on project specifications, an additional strut may be required. Refer to the project-specific drawings.
Image 6.1 General Structure of the Sigma S1 Support

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Sigma S1 Installation Manual
7. Purlin Installation
The Sigma S1 System uses purlins mounted on the
girder to hold the modules in place. Purlin clamps
are used to secure the purlins to the girder.
Note:
Depending on project specifications, additional
purlins may be required. Refer to the project-
specific drawings.
7.1. Purlin Placing and Alignment
Installation Steps
1. Position the purlins horizontally on top of the
rafters and align them. Please refer to the
project drawings for the exact position of the
purlins with regards to:
-Spacing between purlins
-Horizontal overhang (cantilever) over
the outer driven piles
2. Loosen the purlin clamps pre-assembled into
the girder. Clamp both sides of the purlin to the
purlin clamps.
3. Check that the spacing of the purlins does not
get shifted with the final tightening of the
bolts. Readjust if necessary.
4. Adhere to the specified tightening torques
7.2. Purlin Connector
The purlins are spliced together using a purlin
connector.
Mounting Steps
1. Slide the purlin connector halfway into the
installed purlin. Secure the connector to the
purlin by drilling 2 self-tapping screws into the
pre-drilled holes in the connector.
2. Slide the next purlin into the connector leaving
no gaps between the 2 purlins. Secure the 2nd
purlin by drilling another 2 self-tapping screws
into the pre-drilled holes in the connector.
3. Adhere to specified tightening torques.
Image 7.1-1 Installing the Purlins
Image 7.1-2 Mounting the Purlins
Image 7.2-1 Installing the Purlin Connector
Image 7.2-2 Connecting 2 Purlins

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Sigma S1 Installation Manual
8. Module Clamp Installation
For framed modules, the module clamps for the
Sigma S1 uses a clickstone to attach the module
clamps to the purlin. The module clamps are
inserted into the top channel of the purlin and
tightened using an Allen key.
For frameless modules, laminate clamps use a T-
head bolt inserted into the top channel of the
purlin.
Installation Steps
1. Before installing the module clamps, loosen
the bolt such that bottom part of the bolt is
above the noses of the clickstone.
2. For module clamps, insert the module clamps
at a slight angle into the top channel of the
purlin. While holding it firmly, rock the
clickstone upright until it clicks into place.
3. For laminate clamps, align and insert the
T-head bolt into the top channel of the purlin.
4. Tighten the clamps using the recommended
torque settings.
Hint!
The clickstone is made undersized so that
it is easy to lock it in the module rail
channel. By tightening the screw, the
clickstone is forced apart ensuring the
right support.
To remove the clickstone, loosen the
screw until it no longer touches the noses
in the click stone, press the legs of the
clickstone together, tilt at an angle, then
remove it from the channel.
CAUTION
Material damage due to incorrect
installation
Incorrectly mounted module clamps can
cause the PV modules to fall and be
damaged.
Mount all module clamps in accordance
with the instructions.
Image 7 –1 Module Clamp Installation
Image 7 –2 Laminate Clamp Installation
Clickstone Nose

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Sigma S1 Installation Manual
9. Module Installation
The procedure below describes the installation of
modules on a single row. This procedure can begin
on the west end of the array moving east or vice-
versa.
9.1. Framed Modules –Portrait
1. Insert a module end clamp into each purlin.
2. Place the first PV module on the purlin and
slide the module frame against the end clamp.
With the module’s clamping points correctly
positioned under the end clamps, tighten the
end clamps onto the module frame.
3. Insert a mid clamp into each the purlin. Push it
flush against the module, ensuring the clamp
body rests on top of the previously installed
module frame. Place the next module on the
purlin and slide it against the mid clamps.
4. Repeat the above steps for the rest of the row
of modules. At the end of a row, install an end
clamp on the outside of the last module to
complete the row.
Hint!
Use of a spare module clamp or other
item as a spacing gauge between the
modules columns ensures that the
spaces between columns are the
same.
Image 9.1 –1 Module End Clamp
Image 9.1 –2 Module Mid Clamp
Image 9.1 –3 Portrait Installation
Image 9.1 –4 Placing the next PV module

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Sigma S1 Installation Manual
9.2. Framed Modules –Landscape
1. Insert a module end clamp into the bottom
purlin.
2. Place the first PV module on the bottom purlin
and slide the module frame against the end
clamp. With the module’s clamping points
correctly positioned under the end clamps,
tighten the end clamps onto the module
frame.
3. Insert a mid clamp into the next purlin. Push it
flush against the module, ensuring the clamp
body rests on the previously installed module
frame. Place the next module onto the next
purlin and slide it against the installed mid
clamp.
4. Repeat the above steps until the top rail is
reached. At the topmost purlin, install an end
clamp on the outside of the last module to
complete the column.
Image 9.2 –1 Landscape Installation
Image 9.2 –2 Installing next column of modules

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Sigma S1 Installation Manual
9.3. Frameless Modules –Portrait
1. Insert a laminate end clamp into the purlins.
2. Place the frameless module on the purlin and
insert it into the laminate end clamp leaving at
least a 1mm gap.
3. Insert a laminate mid clamp into the previously
installed module. Place the next module on the
purlin and insert it on the installed laminate
mid clamp. When inserting the modules into
the laminate mid clamp, remember to leave at
least a 1 mm gap.
4. With the module’s clamping points correctly
aligned with the laminate clamps, tighten the
clamp to the module.
5. Repeat the above steps for the rest of the row
of modules. At the end of the row, install a
laminate end clamp on the outside of the last
module to complete the row.
9.4. Frameless Modules –Landscape
1. Insert a laminate end clamp into the bottom
purlin. Place the frameless module on the
purlin and insert it into the laminate end clamp
leaving a 1mm gap.
2. Insert a laminate mid clamp into the next
purlin and insert the installed module into it.
Install the next module by inserting it to the
installed laminate mid clamp. When inserting
the modules into the laminate mid clamp,
remember to leave at least a 1mm gap.
3. With the module’s clamping points correctly
aligned with the laminate clamps, tighten the
clamp to the modules
4. Repeat the above steps until the topmost
purlin is reached. At the end of the column,
install a laminate end clamp on the outside of
the last module to complete a column.
5. Repeat steps 1-4 to install another column of
modules.
Image 9.3 –1 Laminate End Clamps in Portrait
Image 9.3 –2 Laminate Mid Clamps in Portrait
Image 9.3 –3 Portrait Installation
Image 9.4 –1 Laminate Clamps in Landscape
Image 9.4 –2 Installing next column of modules

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Sigma S1 Installation Manual
10. Maintenance
When properly assembled, the Sigma S1 is a reliable
and trouble-free system that requires minimal
maintenance. Nevertheless, S-Rack Australia Pty
Ltd recommends performing regular inspections
and creating a maintenance schedule. By doing so,
potential problems can be detected and resolved
before they can become serious, ensuring the
system’s excellent long-term durability and
reliability.
The following procedure pertains only to the Sigma
S1 System structure. Maintenance and repair of
other PV system components should be carried out
in accordance with the respective manufacturers’
recommendations.
9.1. Inspection
The system should be visually inspected for obvious
loose connections, missing components, modules
which appear to have shifted, vegetation
overgrowth, wind-blown debris, and other
indications of abnormality annually. Any problems
detected at this time should be addressed and
repaired as necessary.
9.2. Testing
After one year in service, it is good practice to check
the torque settings of a representative sample of
system connections including module clamps and
rail clamps. Do not exceed the recommended
torque settings. If a disproportionate number of
loose connections (more than 10% of connections)
are found, it may be an indication of an improper
assembly and it may be necessary to take
comprehensive corrective action.
S-Rack Australia Pty Ltd recommends keeping
records of connections sampled each year and
checking untested connections in the succeeding
years. Once all connections have been tested,
sample sizes and test frequency can be reduced.

S-Rack Australia Pty Ltd
Suite W3B4, 75 O’Riordan Street
Sydney Corporate Park
Alexandria 2015
NSW
Tel: [phone]
Fax: [phone]
[email protected]
Subject to technical alterations
2021 © S-Rack Australia Pty Ltd
Ver. Date: 28/01/2021