10179612_1631 S. SPRUCE - Plan (2)

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SFSystem Planning and Assemb(y Installation Manual SUNPOW[ R Material planning for rails and cap strips: Preplanning material usefor,ourparticular army can prevent Rail segments come from five 192-inch lengths, lettered Athru structural orasthed,problents, particulaWy chose caused by very E Rail A, for example, is cut into two 96-inch segments, with shon lengths ofmit or cap str@. This exomple fllusoutes one one segment spliced into each of the first two rails. Similarly, approach.five 192-inch cap strips are designated V through Z. Sructural requirements for rails are detailed infooting and splicing requirements" (p.5). Structural]y, cap strips require: • Ascrew in prepunched hole (which occur every 7 inches, beginning 3-1/2 inches from the ends of the mils)· All cap strip segments are cut at the midpoint between prepunched screw holes. For each rail, start with the cap strip segment that crosses the array center line, and position over the centerline so that the appropriate holes are spaced equally on either side. • One screw 3-1/2 inches or less from the each end of every rail segment Wherever there is no prepunched hole within 3-1/2 inches of an end of a segment, drill a '4-inch hole 2 inches from the end of the segment and install a cap strip screw. (In most cases, you can avoid this situation with good material planning.) Position each cap strip onto its rail and mark its trim point. Remove and trim before final mounting. Structural requiremenfs always take precedence, but usually good planning can alro achieve both material conservation and superior aesthetics. This example conserves material and achieves Mo specific aesthetic goals: • Cap strip screws must align across the rails. • End screws must beequidistant from both sides of the array. The example assumes an array of three rows, each holding five modules 41 inches wide. Thus, four 205-inch rail assemblies and cap stdpassemblies need to be cut and spliced from 192- Inch sections of rail and cap strip. The example illustrates one means ofdoing so, without violating structural requirements or aesthetic goals. A.ay center Une t.-- Trirrine lanay edge) Preliminaafooting and splice positions must bechecked against structural requirements [n Footing and spticing requirements" (p.S). In this example, the center ofthe amy is o#set 2 inches from the center rafter. 7?Us prevents railsplices BD (3rd rail)and CE(4th rail) fromfalling too close to the center of the span, betweenfooti;,gs. Because.footings are not visible.from ground level there fs negugible aesthetic loss Trirn line (aniy edge -1 ... -VIIT•••••... .|. .... X 96" -••••|l,tcapstrip C 85'E 122» |4th ron 1 1 |• •••WHZ"•••••••••|••••• 196•••• •|2ndcapstrip B 85 D 127 |3rd rag 1 1 ·10· · •Y 128- • • • • • |3rd cop strip A 96"1 -63 C 109" |2nd rail 4 16. V ...... 2 128' - • • · · 41h cap strip | A 96-9.1 8 109-11.ral I il Usable fernatnder: D. 70": E, 70: Y. 64: Z. 64 SUNPOWER SFSystemPlanningandAssembly Installation Manual 6. Securing the first module: 3-681#ip screwi \Gather sufficient lengths of cap strip Permissible'bve,hang: ./< _,->-j,to cover the length of the first rail. For ,\ ,2. module widlh n./1-«maximum visual appeal andmaterial 4 , conservation see "Material planning for 5/rails and cap strips" (p· 7). Slide the first module into final position at one end of the array. Lay the remaining modules in the top row, leaving a gap about a foot wide between the first and second modules (Fig. 7). The temporary gap allows the installer to j..0 place one of his feet between modules. He ' -4 can access the section of thecapstriphe 3- 1 f needs to secure while leaning toward the peak of the roof. For the time being, the lastmodule may overhang the rail by up to one third its width. er ,%99'-knollrutalsecond' , 4- - rmodules are placed -4 Attach theend of the cap suip with the 3/.0,2/3.02*3 cap strip screws (Fig. 7, inset),so that the upper end of the first module is secure.Figure 7. Begin cap strip installation. 1 The structurclintegrity of yourarray requires that cop strip screws.ful#engage the threaded rail. Use the cap strip screws supplled with your cop strips. Any substitute screws must be 44-201ype F thread cutting (18-8 stainless steeU and the correct length. Every cap strip segment must have a cap strip screw 3-1/Zinchesor tessfromeachenl uthe nearestpredrilled hotefalls more than 3-1/2 inches from any end, drill a 44-inch hole 2 inches from the end and install an addmonal screw. ur leCL-22'·5 2,-U.J.2--2-I Figure 8. Position and secure modules one by one. Wherever it is necessary to make a new cap strip hole, drill a 44-inch hole b€fore installing the cap strip screw. 7. Instailing the remaining modules in the top row: Slide the nexc module into final position and install the screws to secure it (Fig. 8). For a neat instalation, use cable des to attach excess wiring to the rail beneath the flanges. SunPower's cable ties can be attached to the SF System rail by drilling a V.inch hole in the rail and pushing the end of the tie into the hole. Slide and secure o , by on, A . Secured }st Continue the process until all modules in the top row are in final place andsecured from the top. When complete, every prepunched hole in the cap strip will be secured by a screw. Figure 9. As modules slide into place, the stepping gap shifts always allowing access to the section of cap strip being secorei 8. Installing the remaining modules row by row: Repeat Steps 6 and 7 for the remaing rows (Fig. 9). Each subsequent cap strip will secure the tops to the modules being installed and the bottoms of the modules in the row above. Place the final cap strip in the lowest rail, securing the bottom of the lowest module row. I -