Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Installation Manual
Document Number 9910019 Rev B
February 2014
panelclaw.com
Revision History
Rev
ECO #
Date
C00242
07-MAR-13
INITIAL RELEASE
JA
C00300
07-FEB-14
CA
Description of Changes
Approved By
Table of Contents
Introduction ............................................................................................................................. 4
Document Objective ................................................................................................................ 4
Safety Overview ....................................................................................................................... 5
Sun Bear Components.............................................................................................................. 6
Required Tools ......................................................................................................................... 7
Step 1. Survey Installation Site and Install Foundations ...................................................... 8
Step 2. Attach Struts to Foundations ................................................................................... 8
Step 3. Prepare the Preassembled Frame for Modules ..................................................... 11
Step 4: Install Three Rows of Modules on the Preassembled Frame ................................ 15
Step 8: Lift Frame into Place and Attach Struts ................................................................. 19
Step 9. Install the Last Row of Modules ............................................................................. 20
Step 6: Adjust Struts to Change Frame Position and Tilt ................................................... 24
Step 7. Ground the System................................................................................................. 25
Technical Support................................................................................................................... 26
Introduction
The Sun Bear fixed-tilt ground mount system (Sun Bear) is designed to install faster than any
other system on the market as of the date of this Installation Manual. Its four-component design
includes a preassembled frame and in-field adjustability, for an unmatched combination of
simplicity and flexibility. There are zero loose fasteners and all components are preassembled to
speed construction and eliminate costly onsite drilling, cutting, or welding.
Sun Bear features include:
Accelerated construction time: Designed to be the fastest system to install in the market.
Only four major components and zero loose fasteners.
Material-saving truss design: Strut components carry only tension or compression loads
making them light weight and structurally efficient.
Preassembled frames with telescoping rafters: Reduces overall height and width for easier
shipping yet deploy in seconds in the field.
The Sun Bear system has been extensively tested, undergoing individual component finite element
analysis, computational fluid dynamics modeling, static load modeling, and wind tunnel testing. All
testing has been independently conducted by third parties and provided to PanelClaw, Inc.
(PanelClaw).
Document Objective
This installation manual has been put together to assist in the proper steps required to build a Sun
Bear ground mount system array. The manual covers a best-practice order of assembly for the
construction of the ground mount array and contains detailed notes and tips for a successful
assembly.
Safety Overview
The Sun Bear system architecture and structural engineering is based on a space frame, a trusslike rigid structure constructed from interlocking struts in a geometric pattern. Like the truss, a
space frame is strong because of the inherent rigidity of the triangle;
flexing loads (bending moments) are transmitted as tension and compression loads along the
length of each strut. These structures are used in bridges and skyscrapers for their strength,
efficiency, and reliability. It is important to know however that each member (strut) in a truss
design is required for the system to stay erect safely. No single Strut in the Sun Bear system may
be removed from the truss without the system becoming unstable. This must be kept in mind
when constructing Sun Bear and when following the installation procedures.
Note the appearance of the
within this installation manual. It serves as a reminder to the
unique behavior of a truss system and the safety precautions that must be followed.
PRIOR TO INSTALLATION, READ THE SAFETY PROVISIONS ATTACHED ON APPENDIX A AND REVIEW
THE INSTALLATION MANUAL IN ITS ENTIRETY.
Strut
Foundation
(x 3)
(x 7)
Claw
Frame
Foundation
(1) South; (2) North. North foundations are shared with adjacent tables.
1a.
Built-in keyhole
Strut
(2) South (red); (2) North-South (green); (2) North (blue); (1) Cross (black).
2a.
2b.
Jam nut
2c.
-13 fastener
Frame
3a.
In-board rafter
3b.
Out-board rafter
3c.
Purlin
Claw
4a.
Mid Claw
4b.
End Claw
Wire Management
Hook
Required Tools
Tools Required
25 tape measure
Project drawing
Note:
For your convenience, a complete Sun Bear tool kit and Rigging kit is
available for purchase from PanelClaw.
8 forklift extensions
(4) 10 two-ton straps and J hooks for lifting frame bundles (one frame bundle contains
seven frames). The frame bundle weight is 2,100 lb.
3. Attach all Struts but the Cross Strut (black) into the keyhole on their respective foundation
(Figure 3). Prepare the Cross Strut by placing it near the North-West foundation and with its
color strap and jam nut end next to the foundation.
NOTE: Cross Strut will be attached to foundation in Step 3.
4. Struts are attached to the keyhole on the south side of the keyhole so that the fastener
passes through the hole in a south to north direction.
5. Make sure the spherical seat is properly seated in the lower keyhole opening (Figure 4). A
self-locking feature will prevent the Struts from accidentally sliding out of the keyholes
during assembly.
WARNING: Failure to properly seat the spherical seats in the foundation or the
Frame will result in an unstable structure.
6. Follow the Strut-to-connection installation sequence (Figure 5). The Strut fasteners should
be torqued up to 5ft-lb [6.8N-m] at this time to ensure the spherical seat remains in
position
NOTE: These connections will undergo final torqueing at a later step.
10
11
NOTE: It may be necessary to rotate the rafter block slightly to square the block with the
rafter edge after torqueing. This may be done by placing the Allen head socket into the
extrusion of the rafter block and rotating.
5. With two crew members, lift the Frame by the north edge to shoulder height.
6. With the north end of the Frame raised, attach the North-South Struts (green) to the
Frames south purlin. Move the Frame as needed to align the Struts to the Frames keyhole.
WARNING: Move the Frame as needed to align the Struts. Do not attempt to adjust
the length of Struts in order to reach the Frames keyhole or else the ability to make
adjustments later will not be possible.
7. Secure the North-South Struts (green) to the Frame using the same installation steps that
were used to attach the Struts to the foundations.
8. Figure 8 identifies the correct locations for North-South Strut installation to the Frame.
9. Tighten these connections to a torque of 5ft-lb [6.8N-m].
NOTE: These connections will undergo final torqueing at a later step.
12
13
14
15
4. With the module aligned, tighten the module fastener on the End Claw to a torque of 13 ftlb [17.6 N-m] using a Allen head drive socket.
5. Push the module up to deploy the rafters and position the module into the final position
(Figure 13). When in the deployed position, the locking tab will engage with the locking slot
and the rafter will click.
NOTE: To prevent over extension of the rafters it is helpful to place slight pressure using
your thumb on the locking tab to ensure that it engages with the locking slot on the rafter
being deployed.
6. Place the Mid Claws on the lower side of the module by inserting the Claw blocks into the
rafter and then sliding toward the module. Lift module onto the Mid Claw rafter block
(Figure 14) and (Figure 15).
TIP: For a consistent look, make sure the orientation of all the clamps are the same on each
Mid Claw.
16
17
9. Place the second module in this column onto the Mid Claw rafter blocks. Push the module
Frame up against the rafter block so that no gaps are introduced between rows of modules.
10. Ensure that the modules are aligned vertically.
11. Insert the next Mid Claws for this module (Figure 14) and (Figure 15).
TIP: A X 10 EMT conduit may be used as a guide stick to align modules and space
columns of modules correctly. A 1 X 2 X 10 strip of wood may also be used to guide
module placement.
12. Tighten the Mid Claws between the two modules to 13 ft-lb [17.6 N-m] using a Allen head
drive socket (Figure 17).
13. Tighten the Mid Claws rafter fastener on the exposed side of the second module to 9 ft-lb
[12.2 N-m] using a Allen head drive socket (Figure 16).
14. Place the third module in this column on the Mid Claw rafter blocks. Push the module Frame up
against the rafter block so that no gaps are introduced between rows of modules.
15. Ensure that the modules are aligned vertically.
16. Place the next Mid Claws for this module (Figure 14) and (Figure 15).
17. Tighten the Mid Claws between the two modules to 13 ft-lb [17.6 N-m] using a Allen head
drive socket (Figure 17).
WARNING: Do not tighten the last Mid Claw rafter fasteners as this will secure the
south rafter and prevent it from telescoping out once the Frame is fully erected.
18
18. Repeat these to install the remaining columns of modules leaving a 1 space between each
column (Figure 18).
19
20
21
6. Place the last module in this column on the Mid Claw rafter block.
7. Tighten the Mid Claws between the two modules to 13 ft-lb [17.6 N-m] using a Allen
head drive socket (Figure 24).
22
4. Place the End Claw under the module by inserting the End Claw block into the rafter and
then sliding toward the module. Lift module onto the End Claw rafter block (Figure 25).
5. Tighten the End Claws rafter fastener to a torque of 9ft-lb [12.2 N-m] using a Allen head
drive socket.
6. Repeat for the second End Claw required for that module being installed.
7. Torque the Claws module fasteners to 13 ft-lb [17.6 N-m] using a Allen head drive.
8. Repeat for remaining modules.
23
NOTE: End Claws are utilized to attach the outer edge of the module at the top and bottom
of each column. End Claws will be flush with the rafter edge on the top, but may or may
not result in a flush installation on the bottom of each column (Figure 25).
24
25
Technical Support
To contact PanelClaw Customer Technical Support, call +1 978.688.4900 or email
technicalsupport@panelclaw.com.
26
Appendix A: Safety
General Installation Safety with PanelClaw Products: Safety is an essential part of every
photovoltaic (PV) installation and every construction site. It is imperative to plan ahead for any
safety concerns and hazards to promote safe work practices during installation. This section does
not claim to address or support all safety concerns that may arise during the installation of
PanelClaw mounting systems or any other aspect of the work being performed. Before beginning
work, installers should refer to all local and federal safety, health, and regulatory requirements to
assure compliance. Refer to OSHA Part 1926 and its related Subparts for federal construction
related regulations and standards.
The subsections below outline some of the obvious / major hazards that could exist during the
installation of PanelClaw products, and are divided to bring a level of clarity to such hazards. Some
sections do not apply to all PanelClaw product lines and such exclusions are noted within each
section.
Electrical Hazards: PanelClaw products are purely mechanical and do not contain any electrically
live parts. When a photovoltaic module is exposed to sunlight it is electrically live and cannot be
turned off. As soon as modules are installed using a PanelClaw system, an electrical shock hazard is
present. All personnel on site should coordinate to ensure that such electrical hazards are clearly
communicated. It is advised, at a minimum, that all personnel utilize caution and proper Personal
Protective Equipment as outlined in that section. Only electrically qualified personnel should
perform PV module installation. Refer to OSHA Part 1926 Subpart K Electrical and NFPA 70E for
additional information.
Trip Hazards: All PanelClaw arrays have elevated components that are installed above grade or
above a roof surface. Such hazards should be identified and caution should be taken to avoid
tripping over such components. Refer to the Fall Hazards section specifically if working with the
Grizzly Bear, Polar Bear, and Sun Bear product lines. Make sure to pick up and not drag your feet
when working on site, and always pay attention to your path of movement to note any obstructions
that could create a trip hazard.
Lifting Hazards: The PanelClaw installation process involves lifting of heavy items that could lead to
personal injury and damage to property. All personnel should be trained in the proper procedures
for manually lifting. Evaluate an objects size and weight prior to lifting, and follow these general
guidelines for lifting:
1. Assess the lift and know the object weight.
2. Bend at the knees and get a good grip.
3. Keep back straight and lift straight up with legs without twisting. It is important to lift with
the legs and not the back.
27
4. If an object is too large or heavy, ask for help and do not attempt to lift by yourself. In the
case that mechanical assistance (e.g. crane, forklift, etc.) is required to complete the lifting
operations, all machine operators of such devices should be licensed and trained.
Material Handling: All PanelClaw parts and components are made of aluminum and steel alloys and
utilize stainless steel assembly hardware. These materials are considered non-toxic and require no
special handling procedures. Metal components may have sharp edges, so be sure to handle with
care and utilize proper personal protection equipment, especially gloves, during handling. Refer to
OSHA Part 1926 Subpart H Materials Handling, Storage, Use, and Disposal for additional
information.
Personal Protective Equipment (PPE): All personnel should utilize and implement proper PPE per
OSHA requirements. Refer to OSHA requirements for proper use and implementation of PPE. The
following items are suggested as a minimum to avoid injury based on the installation procedure
outlined in this manual:
1.
2.
3.
4.
5.
6.
7.
If any PPE appears to be defective, stop the use of such equipment immediately, and ensure it is
replaced before work continues. Refer to OSHA Part 1926 Subpart E Personal Protective and Life
Saving Equipment for additional information.
Hand and Power Tools: Access to all hand and power tools should be regulated and controlled at
all times on site to prevent improper use and related injuries. When not in use, all equipment
should be stored in a secured location. Only personnel who have been properly trained in the safe
operation of any potentially dangerous tool should be allowed access. All required tools to perform
the installation of PanelClaw racking are outlined in the installation procedure. All tools should be
inspected daily and before use by the operator. If any tool appears to be defective, stop the use of
such equipment immediately, and ensure it is replaced before work continues. Electrical power
tools should follow proper lock-out tag-out procedures per OSHA requirements. Refer to OSHA Part
1926 Subpart I Tools Hand and Power for additional information.
28