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SF System Planning andAssembly Installation Manual M|]M SFSystem Planning and Assembly Installation Manual
<br />Material planning for rails and cap strips:
<br />P,eplanning material use/6/yourparticularcrraycan prevent
<br />structural oritheticproblems, particularb, those caused by vecy
<br />short lengths Of roit or cap strip. This example illustrates one
<br />approach.
<br />Rail segments come from five 192-inch lengths, lettered A thru
<br />E. Rail A, for example, is cut into two 96-inch segments, with
<br />one segmetit spliced into each of the first two rails. Similarly,
<br />five 192-inch cap strips are designated V through Z.
<br />6. Securing the first module:
<br />Ga[hersufficient lengths of cap strip
<br />co cover the length of the first rail. For
<br />maximum visual appeal and material
<br />conservation see "Material planning for
<br />rails and cap stripi (p. 7).
<br />Cap st,ip screws , '. PerA-lissoble omitiong: :-· 1, ...3-' I
<br />4/3 module Width - .t-" ·'....i--
<br />Stuctural requirements for rails are detailed in 'Fooling and
<br />splicing requirements" (p.5). Structurally, cap strips require:
<br />· A screw in prepunched hole (which occur every 7
<br />inches, beginning 3-1/2 inches from the ends of the
<br />rails).
<br />• One screw 3-1/2 inches. or less from the each end of
<br />every rail segment. Wherever there is no prepunched
<br />hole within 3-1/2 inches of an end of a segment, drill
<br />a 44.inch hole 2 inches from the end of the segment
<br />and install a cap strip screw. (In most cases, you can
<br />avoid this situalion with good material planning.)
<br />Structural requirements always iake precedence, but usually
<br />good planning can also achieve both material conservation
<br />and superior aesthetics. This example conserves material and
<br />achieves two speci fic aesthetic goals:
<br />• Cap strip screws must align across the rails.
<br />• End screws must be equidistant from both sides of
<br />the array.
<br />The example assumes an array of thiee rows, each holding five
<br />modules 41 inches wide. Thus, four 205-inch rail assemblies
<br />and cap svip assemblies need to be cut and spliced from 192
<br />inch sections ofrailand ep strip. The example illustrates one
<br />means of doing so, without violating structural requirements
<br />or aesthetic goals.
<br />May center Ene
<br />All cap strip segments are cut at the midpoint between
<br />prepunched screw holes. For each rail, start with the cap stip
<br />segment that crosses the amy center line, and position over
<br />the center line so that the appropriate holes are spaced equally
<br />on either side.
<br />Position each cap strip onto its rail and mark its trim point.
<br />Remove and trim before final mounting.
<br />Preliminaryfooting and splicepositons must
<br />be checked against structural requirements in
<br />"Footing and splicing requiremenu" (p.5).
<br />In this example, the center of the array is
<br />omet2 inches#om the center· rafter. Thls
<br />prevents rail splices BD (3rd raij and CE (4th
<br />ra;Ofromfalling too closeto the center of
<br />the spans betweenfootings. Becausefootings
<br />are not visiblefrom ground level, there is
<br />negligible aesthetic loss.
<br />. ·· · ··.· \·-' 1>··101%-Donot'install second' ,....3.-:<Cop strip untl lower
<br />Slide the first module into final position
<br />at one end of the array. Lay the remaining
<br />modules in the top row, leaving a gap .
<br />about a foot wide between the first and 4
<br />second modules (Fig. 7).
<br />The temporary gap allows the installer to J
<br />place one of his feet between modules. He
<br />can access the section of the cap strip he
<br />needs to secure while leaning toward the
<br />peakof [he roof. Forthe time being, the
<br />last rhodule may overhang the rail by up -
<br />to one third its width.
<br />Attach the end of the cap strip with the .., 1,- < ,<
<br />cap strip screws (Fig. 7, inset),so that the
<br />upper end of the first module if-secure.Figure 7. Begin cap strip installation.
<br />Thestructur,zlintegrilyqfyourarrayrequiresrhat .-r-<Ylijif ,S·-¢*60*
<br />cap strip screwsfully engage the threaded rail.1 :1 11011 sdie# -...**
<br />Use the cap strip screws supplied with your cap ESES¢109· :· .
<br />strips. Any substitute screws mustbe 44-20 Dpep
<br />thread cutting (18-8 stainiess steeU and the correct
<br />length.S --0-3-<,-stjb¢*p.t. 1,Every copstrip segment must have a cap strip .
<br />screw 3-1/2 inches or less,from each end. (f the
<br />nearestpredrilled holefalls more than 3-1/2
<br />inchesfrum any end, drill a W-inch hole 2 inches Figure 8. Position and secure modules one by one.
<br />from the end and install an additional screw.
<br />p- Trim line (array edgel [ T,imline (atray edge.·-·
<br />Wherever it is necessary to make a new cap strip··· ·VIZ'·········I····X 96- • · |I st cap strip hole, drill a 44-inch hole before instdling the cap
<br />C 83 E l 27' |41h rail strip screw.
<br />1 1 1
<br />Uy:'*A'»0293*\3*M-:r,·"a,„
<br />|· ·· ·WI17· ············· X 96* ·····|2ndcapstrip 7. Installing the remaining modules in the top row:
<br />8 83- 0122" |3rd raD
<br />1 1
<br />|· •• •980"· ··· ·|· ··· ·d¢* ·· Y 128" · ·•• • |3rd Cap strip
<br />A 98 1 Attbu-C 107 |2nd rail
<br />Slide the next module into final position and install the
<br />screws to secure it [Fig. 8). For a neat installation, use cable
<br />ties ro attach excess wiring to the rail beneath che flanges.
<br />SunPower's cable ties can be attached to the SF System rnil by
<br />drilling a 44-inch hole in the rail and pushing the end of the tie c
<br />into the hole.
<br />4·-\Secured \<' ..\
<br />...P,\\,Imbdule / I
<br />Slepping gop
<br />Continue the process until all modules in the top row are in Figure 9. As modules slide into place, the stepping gap shifts,
<br />| • · ··w Bor · · · • .,st|·t'· - • • - • • Z 128" • • • • • | Ath cap strip final place and secured from the top. When complete, every always allowing access to the section of cap strip being secured.
<br />prepunched hole in the cap strip will be secured by a screw.1 90 1A 96-B 109" 1 stroll
<br />li 11
<br />J:able remainder. D, 70-: E, 70-: Y, 64-: Z, 64-8. installing the remaining modules row by row:
<br />Repeat Steps 6 and 7 for the remaing rows (Fig. 9). Each
<br />subsequent cap strip win secure the tops to the modules being
<br />installed and the bottoms of the modules in the row above.
<br />Place the final cap strip in the lowest rail, securing the bottom
<br />of the lowest module row.
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