SLK SOLAR PV MODULE User manual

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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page1of38
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ASSEMBLYINSTRUCTIONSFORSLKSOLARPVMODULE
ROOFMOUNTSYSTEM
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TABLEOFCONTENTS
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NoticesandsafetyPage2
GeneralprocedurenotesPage4
InstallationmaterialsandtoolsPage5
PartdiagramsPage5
ElevationViewsPage7
AssemblysequencePage9
TiltbracketassemblyandinstallationPage10
SubstrateassemblyPage12
Panelassembly:
4x1&3x1Page13
GeneralmoduletospargroundingPage17
TiltAccessFeaturePage18
PanelinstallationPage19 
LaterallinkassemblyPage21
WinddeflectorassemblyPage22
BallastpaninstallationPage28
ConnectorinstallationPage32
SparfielddrillingPage34
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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page2of38
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NOTICESANDSAFETYPRECAUTIONS
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Readthisdocumentbeforebeginninginstallationwork.Planforsafepracticeduringanyinstallationactivitywithrespectto
hazardsfromtripping,falling,lifting,repetitivestress,andanyoverheadorelectricalhazards.Whenworkingclosetobuildingroof
edges,considerprotectionoptionsthatreduceworkerexposuretofallhazards.RefertoOSHASub‐Chapter7,Group1,Article2.
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TheSLKSolar®RoofMountSystem(RMS)ismadefromaluminumalloy,fastenedtogetherwithstainlesssteelassemblyhardware.
AluminumalloycomponentsaremanufacturedperASTMB209andASTMB221.5052‐H32isusedforsheetmetalcomponents,and
tempered6000seriesalloysareusedforextrudedcomponents.IntheformsusedinSLKSolar,thesematerialsareconsideredtobe
non‐toxic.Metalcomponentsoftenhavesharpedges.Handlecarefully!Wearingglovesisgoodpractice.
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Thisdocumentisnotprescriptiveregardingsafetyanddoesnotpurporttoaddressallthesafetyconcernsthatmayarisewithits
use.Contractorsshouldbecomefamiliarwithallapplicablesafety,healthandregulatoryrequirementsbeforebeginningwork.
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Electricalsafetynotice–AnytimeaSLKSolarpanelcontainstwoormoreelectricallyinterconnectedmodules,ashockhazardis
present.SLKSolarisamechanicalsystemandcontainsno“live”parts.Mechanicalinstallersandelectriciansshouldcoordinatein
ordertoensurethatallpersonnelareawareofelectricalhazards.
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Precedence–TheSLKSolarRMSpositionsandsecuresphotovoltaicmodules.DC“stringing”andinterconnectionofthemodules
requiresplacementofconduit,conduitfittingsandcombinerboxes.Nothinginthisdocumentisintendedtolimittheallocationof
rooftopspaceortocontrolcraftswithrespecttoworkprecedenceandcoordination.
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Buildrate–Estimatedmechanicalinstallationrate(modulesperday)foranarrayconsistingofcommercial‐classmodulesinstalled
withaSLKSolarRMSandassumingawell‐equippedfour‐personcrewisontheroofandworking7.5hours/daywithfulltask
interchangeability:>120modules/day.
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As‐builtdocumentationprocess–On‐roofuseandmark‐upofthisdocumentandthedrawingsandprintedmatterreferredtoin
thisdocumentisgoodpractice.Markupandannotatethedrawingsonaregularbasis,notingcompletions,exceptions,dimensional
inconsistencies,etc.
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Fieldmodifications–UnauthorizedfieldmodificationofSLKSolarcomponentsorassembliesmayaffectSLKSolarwarranty
coverage.ProvidemarkedupdrawingsforSLKSolar’sreview,commentandapprovalpriortoattemptinganyfieldmodifications.
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Workarounds–Workerslayingoutorinstallingarraysonrooftopsmayencounterundocumentedorunexpectedobstacles
requiringaworkaround.SincePVarraysareintendedtobeprimarilyregularandrepeatingstructures,workaroundsshouldbe
notedonworkingdrawings.Whenaworkaroundaffectsthelocationoftwoormoremodulesatonce,thesupervisorshouldbe
advisedandtheworkaroundshouldbeevaluatedandthencompletedinamannerthatensuresthattheremainderofthearrayis
notaffected.
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Roofsurface–Alllargeflatroofshavepitchandundulation,jointedassemblies,andmayalsohavelevelseparationsandparapets.
Variousroof‐mountedfittings,airventpipesandequipmentsuchasHVACorprocessequipmentmayalsobeencountered.The
preciselocationofmanyrooftopdetailsisnotknownsincesuchdetailsareinstalledunderconditionsinwhichtheworkeror
contractormayhavediscretionregardingfinallocation.
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FireSafeRoof–TheSLKSolarRMSistobemountedoverafireresistantroofcoveringratedfortheapplication.TheSLKSolarRMS
isnotmeantforslopedroofswheretheslopeisgreaterthan1½”:12”(7°or12%).
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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page3of38
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Fit‐up–SLKSolarisadesigned‐fitsystemandisassembledusingfastenersandassemblyboltsets.Matchingholelocationsare
engineeredtoensurelong‐termreserveassemblystrengthandlifecyclereliability.Sinceundulationandslopeisrequiredtoensure
roofdrainage,SLKSolarincorporatesfeaturesthatallowthearraytofollowtheroofcontour.Line‐upforfinalboltedconnection
typicallyinvolveslight“buckingin”duringassembly.Adriftpinisausefultoolwithwhichtoalignholesforcross‐bolting.
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Rooflifeandcare–Theservicelifeofanyroofiscontingentuponcarefortheroofespeciallyduringequipmentinstallationona
roof.Avoidconcentratedloadsontheroof.NeverdragSLKSolarcomponentsintoplace.Instead,elevatethecomponent,andthen
moveitmanuallyorwithacart.Locateitandthenplaceit“onspot.”Toensureroofingsystemwarrantycontinuation,workwith
roofingsysteminstallationcontractorstoensureroofingsystem–arraycompatibility.
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WARNING!Single‐plyroofsarenotdamagetolerant.Avoidaccumulationofmetalfinesthatresultfromdrillingorsawingmetal
components.Metalfinesembeddedinthesolesofshoescandamagesingle‐plyroofs.
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Fasteners–AllrequiredfastenersarefurnishedwiththeSLKSolarRMS.Allfastenersare18Cr‐8Nistainlesssteel.Foranyassembly,
finishinitialboltedassemblytofingertight.RefertotheInstallationManualfordetailedinformationonapplication.Button‐head
capscrews(BHCS)areprecision,low‐profilefasteners.Useofair‐poweredtoolsthatdonotincorporatemeanstolimitapplied
torquemaydamagetheheadofthesefastenersandisnotrecommended.
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Finalinspection–VisuallyinspectassembledSLKSolararrays,roof‐mountedorgroundsupported.Thesuggestedprocessconsistsof
arow‐by‐rowwalk‐throughandthenaperimeterwalk‐around,aftermechanicalassembly,beforeelectricalcompletion.Reportany
distortionintheassemblytoSLKSolar.Arraysubstratesupportsshouldbeinfullcontactwiththeroofortheground.Anyindication
ofunevendistributionofweightshouldbeevaluatedandcorrectedbeforecontinuingwithelectricalfinishing.

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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page4of38
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GENERALPROCEDURENOTES
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A.TheSLKSolarsystemassemblesmodulesintopanelsasfollows:
 4x1–4modulesassembledintoonepanel
 3x1–3modulesassembledintoonepanel
2x1–2modulesassembledintoonepanel
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B.Tiltbrackets
Tiltbracketsaremulti‐functionSLKSolarassemblies.Togetherwithlongitudinallinks,tiltbracketsmakeuptheSLKSolar
roofsubstrate.Tiltbracketsenablefree‐standingarraysupportandallowformechanicalanchoring.Tiltbracketbasescan
beadaptedtoanyrooftype.Tiltbracketcoverssetthearrayangleofincidence,connectSLKSolarpanelstothesubstrate
sub‐systemandestablisharrayrowspacing.
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Tiltbracketsareconfiguredforeasyfieldassemblyandareshippedintwoparts.Tiltbracketcoversareshippedinasemi‐
formedconditionandneedfinalformingtobecompletedon‐siteandarethenattachedtothetiltbracketbases.This
minimizesonsitestorageandreducesshippingandhandlingbulk.
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Assemblytimefortiltbracketisabout10seconds.Theassemblyprocessisworkerfriendly.Asistrueforanyprecision
assembly,alighttouchworksbest.
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Donotover‐bendthetiltbracketcover.
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C. TILTACCESS™isauniquefeaturetoSLKSolarthatletsyouflipthepanelsupandoutoftheway.
Duringinstallationdonotleavepanelsunattendedinthetiltupposition.Donotplacepanelsinlockedtiltuppositionif
windsexceed15mph.
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D.Temporaryballast
Attheendofeveryworkday,ensureallcomponentsaresecurelyattached.Temporaryballast(i.e.sandbags)maybe
requiredtosecurethesystemtotheroofduringtheinstallationprocesstopreventmovementordamageduetowind.
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E.Safety
Foralldayhandlingofaluminumcomponents,weargloves.
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Becarefulofpinchhazards,especiallywhenloweringpanelsontotiltbrackets
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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page5of38
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REQUIREDINSTALLATIONMATERIALSANDTOOLS
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1. Minimumsix(6)sawhorses(e.g.Stanley2wayadjustablesawhorses,32”high,4”longand29”wide.Stanleypart
number11012)
2. Torquewrench
3. Cordlessscrewdriverwithtorqueadjustment
4. Rubbermallet
5. 1/2”wrench
6. 9/16”wrench
7. 1‐1/8”wrench
8. Hexbitdrivers‐3/16”,5/32”,7/32”
9. Driftpin
10. Wirecutters
11. Pliers

PARTDIAGRAMS
Spar
(aluminumextrusion)

Longitudinallink
(aluminumextrusion)




Anchorblock
(aluminumextrusion)




Laterallink
(aluminumextrusion)
Pivotblock
(aluminumextrusion)
Clampblock
(aluminumextrusion)






Tiltbracketbase
(aluminumsheetmetal)



Tiltbracketcover
(aluminumsheetmetal)



Endrowtiltbracketcover
(Aluminumsheetmetal)







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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page6of38
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PARTDIAGRAMS
Eastwinddeflector
(aluminumsheetmetal)



Westwinddeflector
(aluminumsheetmetal)



EndEastdeflector
(aluminumsheetmetal)


EndWestdeflector
(aluminumsheetmetal)



Enddisc
(aluminumextrusion)






Deflectorclip
(Stainlesssteel)


Drilljig





Longlinkclamp
(stainlesssteel)




ZClampArm
(stainlesssteel)
Ballastpan
(aluminumsheetmetal)





Flashablepostanchor(FPA)
(machined/weldedaluminum)





















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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page7of38

ELEVATIONVIEWOF5°SYSTEM
(notetiltbracketsaretransparentforclarity)










ELEVATIONVIEWOF10°SYSTEM
(notetiltbracketsaretransparentforclarity)

















PVModule
Tiltbracket
Pivotblock
Anchorblock
EndDisc
Wind
deflector
Spar
Clamp
block
Lateral
link
Endrowtiltbracket
(smallersizethantiltbracket)
Wind
deflector
Northendrow
tiltbracket
An
c
h
o
r
b
l
oc
k
Tiltbracket
Clamp
block
PVModule
Pivotblock
EndDisc
LongLink
Spar
Tiltbracket
Endrowtiltbracket
(smallersizethantiltbracket)
LongLink

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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page8of38
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ELEVATIONVIEWOF15°SYSTEM
(notetiltbracketsaretransparentforclarity)










ELEVATIONVIEWOF20°SYSTEM
(notetiltbracketsaretransparentforclarity)








Wind
deflector
Laterallink
Clampblock
Pivotblock
Anchorblock
Enddisc
Spar
Tiltbracket
PVModule
Endrowtiltbracket
(smallersizethantiltbracket)
Laterallink
Clampblock
PVModule
Pivotblock
Enddisc
SparAnchorblock
Tiltbracket
Endrowtiltbracket
(smallersizethantiltbracket)
Wind
deflector
Endrowtiltbracket
(smallersizethantiltbracket)
Endrowtiltbracket
(smallersizethantiltbracket)
Longlink
Longlink

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
AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page9of38

ASSEMBLYANDINSTALLATIONSEQUENCE

1. Assembletiltbracketbendingjig.
2. Assembletiltbrackets.
3. Installtiltbracketsandlongitudinallinksonroof.
4. Layoutmodulesandsparsonsawhorses.
5. Attachclampblockstospars.
6. Attachmodulestospars.
7. Installgroundingscrews
8. Attachpivotblocksandanchorblockstospars.
9. Attachpanelstotiltbrackets.
10. Hookupmoduleleads.
11. Attachlaterallinks.
12. Attachwinddeflectorsonnorthrows.
13. Installenddiscs.
14. Installballastpansand/orconnectorpostassemblies.

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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page10of38

TILTBRACKETASSEMBLYANDINSTALLATION

Step1.–Tiltbracketjigassembly
Beforebeginningassemblyofthetiltbracketsabendingjigmustfirstbemadewhichwilleaseassembly.(10degreesystemshown)

Thebendingjigismadeasfollows;taketwotiltbracketcoversandbendthemoveralongitudinallink(refertoStep2),beingcareful
nottooverbend.Attachthetiltbracketcovertothetiltbracketbaseasshowninstep3below.Attachalongitudinallinkbetween
thetwotiltbracketsasshownbelowusingtwo(2)3/8”‐16x2.25”HHCSand3/8”Hexnuts,(note:longitudinallinkisonlyattachedto
theupperholeinthetiltbracketswhenusedasjig).Thebendingjigisnowreadytobeused.

Step2.–Bendtiltbracketcovers
Layatiltbracketcoveroverthelongitudinallinkandbendthesidesofthecoverinwards,beingcarefulnottooverbend.Thetilt
bracketcoverwillhavealittlespringback.
Longitudinallink
Tiltbracketcover
PartsUsed
Tiltbracketcover
Tiltbracketbase
Longlink
3/8”‐16x2.25”HHCS
3/8”‐16Hexnut

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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page11of38
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Step3.–Createtiltbracketcoverandbaseassembly
Attachthetiltbracketcovertothetiltbracketbase.Centerthetiltbracketcoveroverthetiltbracketbaseandpinchthelegsofthe
tiltbracketcoveruntiltheslotsinthecoverclearthelockingtabsinthebase.Allowthecovertoexpandwiththelockingtabsofthe
baseengagingwiththeslotsinthecover.Pushdownonthecenterofthecovertocompleteengagementoftabs.Ensurealllocking
tabsareengagedproperly.
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Pinchcoverandalignlockingtabswithslots   Releaseandengagelockingtabs,pushcover
downtocompleteengagement

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
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Assembledtiltbracket

  


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Pinchslightly Release

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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page12of38
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SUBSTRATEASSEMBLY 
Step1.–Createthesubstrate
Setuptiltbracketsatdesiredlocationandattachlongitudinallinksbetweentiltbracketsasshownbelow.Usefour(4)3/8‐16x2.25”
HHCS,eight(8)3/8”flatwashersandfour(4)3/8”hexnutstoattachthelongitudinallinktothetiltbrackets.Useawasheroneach
sideofthetiltbracket.Donotfullytightenthenuts.Repeatforsecondcolumnoftiltbrackets.

PartsUsed
Tiltbracketcover
Tiltbracketbase
Longlink
3/8”‐16x2.25”HHCS
3/8”‐16Hexnut
3/8”Flatwasher

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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page13of38
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PANELASSEMBLY
(4x1panelsystemshown)

4x1and3x1PanelAssembly:
Step1.–Sawhorsepreparation
Layoutsawhorsesasshown,distancebetweenfirstandlastsawhorseshouldbeapproximately12”shorterthansparbeingused.
Asparcanbesetongroundbesidesawhorsesandusedasguide.Note:Itmaybehelpfultoplaceplywoodsheetsonthesaw
horsestoprovidealargerworksurfaceforholdingtoolsandcomponents.

 

Step2.–ModuleandSparPreparation
Sparsareusedasthemaincomponentofthepanelassemblies.Modulesareaffixeddirectly.
Laymodulesfacedownwithanapproximatemoduletomodulegapof1.25”.Laytwo(2)sparsontopoftheedgesofthemodules.
Orientmodulessuchthatjunctionboxesareinsamedirectionforallmodules.

  


  


Spar
PVModule
PartsUsed
Spars
Clampblocks
5/16”‐18x1.25”BHCS
3/8”‐16x2.25”HHCS
3/8”‐16HexNut
Mountingfasteners:
5/16”‐18x.625”BHCS
5/16”Hexflangenut
Or¼”‐20x.625”BHCS
Or¼”‐20Hexflangenut
Orientandlay
sparsoneither
sideofthesaw
horses
Sawhorse
Orientspars
PVModule

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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page14of38
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Step3.–Clampblocks
Theclampblocksareusedtoprovideequalspacingbetweenmodules.
Installthree(3)clampblocksper4x1sparandtwo(2)clampblocksper3x1sparand1clampblockper2x1sparusingone(1)5/16‐
18x1.25”BHCSperclampblock.Leaveclampblocksloose.
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


Clampblock
Module
S
p
ar


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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page15of38
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Step4.–Attachmodulestospars
Attachmodulestosparsintheorientationshownbelow.Dependingonmoduleandmountingholediameter,useeitherfour(4)
5/16‐18x.625”BHCSorfour(4)1/4–20x.625”BHCSwithcorrespondingflangenutspermodule.Sparswith.28”mountingholes
use1/4”screwsandsparswith.34”holesuse5/16”screws.Leavenutsloose.Onceallboltsandnutsareinstalled,verifythatthe
clampblockflangesarepositionedflushovereachmoduleandsquarewiththespar.Tightenallboltsto11‐14ftlbsusingcordless
screwdriver.Ensurecordlessscrewdriverissettothecorrecttorque.Duringthisprocessmakesurethesparsareseated,withno
gaps,againsttheoutsideofthePVmoduleframes.
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Step5.–Installpivotblockstospars
Installtwo(2)pivotblocksontothefirstspar.Itmaybenecessarytolightlytapthepivotblockintoplaceusingarubbermallet.
Attachpivotblockstosparusing3/8”‐16x2.25”HHCS,two(2)perpivotblock.Tightento16‐20ftlbs.
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Sideviewofpivotblockandspar.
Pivotblock
Spar
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Pivotblock
Spar

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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page16of38
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Step6.–Installtheanchorblocks
Installtwo(2)anchorblocksontothesecondspar.Rotateanchorblocksothatgroovedsurfaceisfacingmodules.Attachanchor
blockstosparusingtwo(2)3/8”‐16x2.25”boltsand3/8”hexnuts.Tightento16‐20ftlbs.
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Note:Dependingonmovementofpanelsonsite,theanchorblockscanbeattachedtothetiltbracketsfirst.Theanchorblocks
wouldthenbeattachedtothesparafterthepanelisinstalledonthetiltbrackets.
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Anchorblock

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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page17of38
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GeneralModuletoSparGroundingRecommendations
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Pleasereferto“GeneralModuletoSparGroundingRecommendations–RevA”

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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page18of38
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TILTACCESSFEATURE
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TILTACCESS™isauniquefeaturetoSLKSolarthatletsyouflipthepanelsupandoutoftheway.Thisenablesaccesstothe
undersideofthemodulesduringinstallationandroutinemaintenance.TousetheTILTACCESS™feature:
1. Removeboth3/8”‐16x2.25”HHCS’sfromtheAnchorBlock/TiltBracketassembliesandonefromeachofthePivot
Block/TiltBracketassemblies(referencebelowimageforexactholelocations).
2. Liftthesub‐assembly(4x1and3x1)upto100degrees.Toholdthemodulesinpositionaligntheprovidedlockingholeson
theTiltBracketwiththelockingholesoneachPivotBlock.
3. Placeone3/8”‐16x2.25”HHCSintothelockingholesoneachofthetwotiltbrackets.
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Note:TILTACCESS™featureisallowedwithoutadditionalsupportinwindspeedlessthan15mph.
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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page19of38
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PANELINSTALLATION
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Step1.–Attachingthepaneltothesubstrate
Attachtheassembledpaneltotheinstalledtiltbrackets.Orienttheassembledpanelup90°andguidethepivotblocksintothetilt
bracketsonthesouthside.
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Step2.–Attachingtheanchorblockstothesubstrate
Rotatethepaneldownandguidetheanchorblocksintothenorthsidetiltbrackets.Installtwo(2)3/8‐16x2.25”HHCSwitha3/8”
flatwasherintoeachanchorblockandattacha3/8”flatwasherand3/8”hexnutoneachbolt.Donottighten.Installtwo(2)3/8‐
16x2.25”HHCSwith3/8”flatwashersintoeachpivotblockandfastenwith3/8”flatwashersandnuts.Onceallboltsareinstalled
andpanelsareincorrectpositiontightenalleight(8)mountingboltsto16‐20ftlbs.
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PartsUsed
Assembledpanel
Substrate
Enddisc
3/8”‐16x2.25”HHCS
3/8”‐16Hexnut
3/8”Flatwasher

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AssemblyinstructionsforSLKSolarroofmountsystem‐RevL  Page20of38
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Step3.–Installingenddisctosubstrate
InstallenddiscintoopenendofeachtiltbracketlocatedonthesouthsideofeachSLKSolarcolumn.Secureenddiscwithone(1)
3/8‐16x2.25”HHCSwithtwo(2)3/8”flatwashersandone(1)3/8”hexnut.Tightento16‐20ftlbs.
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Enddisc
Endrowtiltbracketcover
(Southrow)