POWER XPRESS TM Assembly Instructions step-by-step assembly and installation Version 2, Rev A SP3285-5 PCN 022417-1
POWER XPRESS TM Ratings The POWER XPRESS TM conforms to ANSI/ UL UL2703 (2015) Standard for Safety First Edition: Mounting Systems, Mounting Devices, Clamping/Retention Devices, and Ground Lugs for Use with Flat-Plate Photovoltaic Modules and Panels. Electrical Note: Electrical installations must be in accordance with the National Electric Code ANSI / NFPA 70. Contact your local Authorities Having Jurisdiction (AHJ) for additional details. Max Overcurrent Protective Device (OCPD) Rating: 25A Equipment Grounding Conductor Sizing Module Fuse Rating Copper Wire Size <15 AMPS #14 AWG 90 C <20 AMPS #12 AWG 90 C 20-60 AMPS #10 AWG 90 C Module Clamps Module clamps have integrated grounding and have been tested to UL 2703. See Module Compatibility List for list of approved modules. Module Orientation: Landscape Fire Class Resistance Rating The system fire class rating is only valid when the installation is conducted strictly in accordance with this manual. The assembly is to be mounted over a fire resistant roof covering rated for the application. Meets the requirements of Class A Low Slope Flush-Mounting Applications when using Type 1, Listed Photovoltaic Modules. Low Slope refers to roofs with slopes less than 2:12. Structural Certification Mechanical Load Rating: Exceeds the minimum design load rating of UL2703 section 21.4 (30 psf downward, 20 psf upward, and 8 psf downslope) load. Actual system structural capacity defined by PE review. Marking Product markings identified per UL2703 are to be located in a location that is readily accessible for inspection. Periodic Inspection Periodic re-inspection is a recommended system maintenance procedure to check for loose components or corrosion. If any loose components and/or corrosion is found, the affected components are required to be replaced immediately, with the original mounting system manufacturer s component parts. Assembly Instructions, POWER XPRESS (Version 2, Rev A) i
POWER XPRESS TM WARNING Do not install the POWER XPRESS system on any roof with a pitch ratio exceeding 1/12 (approximately 5 degrees) as this could lead to a catastrophic structural failure and severe personal injury or death. WARNING Be certain that the tilt angle and corresponding ballast are carefully followed in accordance to the project specific design specifications. Failure to do so could lead to catastrophic structural failure and severe personal injury or death. About the product The POWER XPRESS is a non-penetrating structure, i.e., the structure does not get screwed, bolted or otherwise fastened to the roof substrate. Instead, it is weighted/held in place to the roof substrate using concrete-cap blocks as ballast. Important Installation Considerations Minimum Setback of 3 feet Roof slope cannot exceed 5 Consulting with a local building department and/or professional engineer is recommended. Grounding Considerations The POWER XPRESS requires no additional grounding devices and has been evaluated to meet UL 2703 standard for PV mounting systems. For questions on a specific installation, please: Contact us by Phone: 800-260-3792 Send an Email request: info@plpsolar.com About these instructions: They are intended to be used by individuals with sufficient technical skills for the task. Knowledge and use of hand tools, measuring devices and torque values is also required. They include various precautions in the forms of Notes, Cautions, and Warnings to assist in the assembly process and/or to draw attention to the fact that failure to follow certain assembly steps may be dangerous and could cause serious personal injury and/or damage to components. Following the step-by-step procedures and these precautions should minimize the risk of personal injury or damage to components while making the installation safe and efficient. Periodic Inspection Periodic re-inspection is a recommended system maintenance procedure to check for any loose components and any corrosion. If any loose components or any corrosion is found, the affected components are required to be replaced immediately, with the original mounting system manufacturer s component parts. Required Tools o 1/2 inch wrench or socket for 5/16 inch module clamp hardware o Torque wrench o Ratchet wrench o Ratchet extension bar o Tape Measure o Square WARNING 1. Preformed Line Products (PLP) is not liable for, and makes no warranty on, expressed or implied, the suitability of roofing, in situ weatherproofing materials, effect of adjacent buildings and/or equipment geometry, and other installation issues which are outside of PLP s scope. PLP s sole liability is set forth in its terms and conditions of sale. Please contact the roofer or warranty holder of the roof or building envelope system prior to the installation of a solar structural array, to confirm acceptance and compatibility of the penetration, attachment, and roof contact methods provided and/or proposed in this manual. 2. PLP offers no liability/warranty on any racks not installed to approved layout by PLP. Furthermore, PLP has no obligation to evaluate adjacent building or equipment geometry that may affect the wind dynamics and pressures exerted on the solar array and disclaims any liability related thereto. 3. The POWER XPRESS system is to be installed over adhered or fixed roof surfaces only. If additional roof protection materials are added under the Ballasted Power Rail structure, including slip sheets, drain mats or sacrificial layers, those materials must either be adhered to the main roofing material or trimmed to fit only under the Ballasted Power Rail rails and ballast trays. 4. Stainless Steel hardware can gall when tightened too quickly. Installer should use a Silver Grade anti-seize compound prior to assembling any stainless steel hardware. Do not use an impact driver. All other driver types should be set to low speed settings. 5. Periodic re-inspection is a recommended system maintenance procedure to check for any loose components and any corrosion. If any loose components or any corrosion is found, the affected components are required to be replaced immediately, with the original mounting system manufacturer s component parts. ii Assembly Instructions, POWER XPRESS (Version 2, Rev A)
Table of Contents Before You Start Main Components... 1 Small Components... 1 POWER XPRESS Chassis... 2 Assembly Jigs... 2 Understanding Ballast Requirements... 3 Ballast Blocks...4-6 Optional Components... 7 Marking the Modules... 8 Using the Module Spacing Jig... 9 Establishing Chalk Lines... 9 Assembly Steps 1. Positioning the Chassis on Roof Top... 10 2. Attaching Clamp Assembly to Chassis... 11 3. Installing the first Module... 12 4. Installing the next Module... 13 5. Placing Minimum Ballast (Temporary Ballast)... 14 6. Installing Deflectors...15-16 Appendices A-1: Installing EPDM Strips... 17 A-2: 5-Degree End Chassis... 18 A-3: High Wind Ballast Tubes... 19 A-4: Installing the Brace Kits... 20 A-5: Grounding/Bonding Path... 21 A-6: Compatible Modules... 22 A-7: WEEB-LUG-8.0 Installation... 23 Assembly Instructions, POWER XPRESS (Version 2, Rev A) iii
POWER XPRESS Main Components POWER XPRESS Chassis - Factory Pre-Assembled Includes attachment points for Module Clamps and Deflector Clips, as well as fully integrated ballast pan (shown with optional EPDM rubber footing, in Appendix A-1). Full Chassis Used on all areas except where Half Length Chassis are required. Certification Marking Label located here End Chassis Used at E-W row ends. A suitable grounding/ bonding device comparable to the Burndy WEEB LUG-8.0 must be used as part of the system grounding path (see Appendix A-7). Deflector Attach to Chassis with special Clip; no hardware required. There are three main components and attaching hardware. Module Clamp - Factory Pre-Assembled Slides onto Chassis Uprights, four per Module. No loose hardware, quickly secures PV Module by tightening single bolt with just one tool. Deflector Clip Passes through Deflector and snaps securely in matched receivers of Chassis Uprights. Assembly Instructions, POWER XPRESS (Version 2, Rev A) 1
POWER XPRESS Chassis Module Clamp mounting slots Deflector Clip mounting slots Slot for optional EPDM Strips Ballast Supports Assembly Jigs Module Marking Jig Use with felt tip marker to mark alignment marks on modules prior to installation. (see page 7) Module E-W Spacing Jig Sets E-W space between PV Modules. Jig is placed on top of two Modules. The descending tabs set space between the two Modules. (see page 8) 2 Assembly Instructions, POWER XPRESS (Version 2, Rev A)
Understanding Ballast Requirements CAUTION Without exception, ballast must be installed/applied per the job layout. Be absolutely certain that the concrete blocks meet the specified weights. Failure to do so could lead to a catastrophic structural failure and severe personal injury or death. Furthermore, failure to meet specifications voids the system warranty. This sample layout shows the specific number of Ballast Block required per Chassis by Chassis location. These numbers will range from 1-8 blocks. For further details on minimum/maximum block quantities and arranging of ballast blocks, please see the illustrations on the following pages where each Chassis type and its ballast has been illustrated. Assembly Instructions, POWER XPRESS (Version 2, Rev A) 3
Stacking/Positioning Ballast Blocks, 10-Degree Chassis 10-Degree End Chassis: Minimum of 2 Blocks, maximum of 4 Blocks. NOTE Arranging and Stacking: Always center (from east to west) all blocks over Pan. Fill width of Pan first before adding 2nd row on top. Always position 2nd layer of blocks toward the taller side of Chassis. 10-Degree Full Chassis: Minimum of 2 Blocks, maximum of 8 Blocks. 4 Assembly Instructions, POWER XPRESS (Version 2, Rev A)
Stacking/Positioning Ballast Blocks - High Wind Ballast Tubes This page demonstrates how to stack and configure ballast between two Full Chassis and between an End Chassis and Full Chassis on 10 degree High Wind systems. Note that the ballast requirements vary depending on whether the system is using 60 cell or 72 cell modules. Ballast requirements also vary by location, that is, the northern rows allow for more ballast than between rows. NOTE The optional High Wind Tubes (Full or End) must be installed prior to installing the modules. Refer to Appendix A3 for installation procedure. Assembly Instructions, POWER XPRESS (Version 2, Rev A) 5
Stacking/Positioning Ballast Blocks, 5-Degree Chassis NOTE Arranging and Stacking: Always center (from east to west) all blocks over Pan. Fill width of Pan first before adding 2nd row on top. Always position 2nd layer of blocks toward the taller side of Chassis. 5-Degree End Chassis: Minimum of 1 Block, maximum of 2 Blocks. 5-Degree Full Chassis: Minimum of 2 Blocks, maximum of 4 Blocks. 6 Assembly Instructions, POWER XPRESS (Version 2, Rev A)
Optional Components (not found on all systems) Assembly Instructions, POWER XPRESS (Version 2, Rev A) 7
Marking the Modules with Marking Jig Place the Marking Jig as shown and strike marks with a felt tip marker by either sliding the Marking Jig down the stack of modules and marking each module or simply mark the top and bottom modules and use a straight edge to draw a line down the entire stack of modules. NOTE Marks are used only to center the Chassis (east to west) between adjacent Modules. Marks become less relevant as the gaps between Modules are set and the Modules are squared to the Module chalk line snapped on roof surface. It s also possible to Mark a Stack of Modules 8 Assembly Instructions, POWER XPRESS (Version 2, Rev A)
Using the Module Spacing Jig To set the gap between Modules, use the Module Spacing Jig, Place the Jig between the previously installed Module and push the second Module up against the tabs of the Jig to set the gap. Establishing perpendicular Chalk Lines on Rooftop Snap perpendicular chalk lines using the 3-4-5 triangulation method. In this example, a factor of 5 feet has been used. On larger systems, use a factor of 10 feet. The chalk lines represent the E-W and N-S coordinates of the array. CAUTION Do not rely on the roof edges or parapets when snapping chalk lines, as they are not always square. Assembly Instructions, POWER XPRESS (Version 2, Rev A) 9
Tip! Assemble by Rows from North to South Start by aligning the southernmost Chassis to the E-W Chalk Line. Then align the first column of PV Modules to the N-S Chalk Line. Always work from south to north. This maintains alignment to the original chalk lines while also ensuring a square and uniform array. 1 Start Positioning the Chassis on Roof Top NOTE Final spacing and alignment of the Chassis will be set as PV Modules are installed. If Microinverters are being used on a 5-degree system, it s best to install the Mounting Brackets prior to Step 1. See Appendix B-2. This is a rough positioning of the Chassis within the array. The only exception being the southernmost row which must be aligned with its chalk line. Spacing between the Chassis as shown in diagram above, is also rough. 10 Assembly Instructions, POWER XPRESS (Version 2, Rev A)
2 Attaching Clamp Assemblies to Chassis PEM Nut Bolt Clamp Clamp Bracket Clamp Assemblies are installed on each of the four Module Supports of the Chassis - the only exception being those Chassis which are positioned on the northern and southern most rows. On those rows, just two Clamp Assemblies are required per Chassis. The northern most row requires Clamp Assemblies on the tall Module Supports while the southern most row requires Clamp Assemblies on the short Module Supports. Assembly Instructions, POWER XPRESS (Version 2, Rev A) 11
3 Install the First Module (shown working E-W) NOTE Before installing Modules, refer to site specific layout drawings to see if either of these items are required: High Wind Ballast Tubes (see Appendix A-3) -or- Brace Kits (see Appendix A-4) If either is required, they must be installed before the Modules are installed. See Appendix for more information on High Wind Ballast Pans and Brace Kits. Tighten Module Clamps Torque to 12 ft.-lbs. Look down the Module and align it to this chalk line Install the first Module 1. Starting in the southernmost corner, put the first Module in place using the four Module Clamps as supports. 2. Be certain that the Module frame has engaged the four Module Clamps as shown in the diagram at bottom right. 3. While maintaining alignment of the Chassis to their chalk line and the Module to its chalk line, adjust the four Chassis into alignment with the marks previously made on the Modules. 4. Tighten the two sets of Module Clamps. Module Support Maintain alignment of Southernmost row of Chassis to chalk line Cross-section of Module Frame Module Clamp Ensure that Module Frame has engaged with Clamp as shown 12 Assembly Instructions, POWER XPRESS (Version 2, Rev A)
4 Install the next Module (shown working E-W) 1. Put the second Module in place; again using the four Module Clamps as supports. 2. Set the gap between Modules using the Module Spacing Jig. 3. Tighten the Module Clamps by sets, starting with the set closest to the Module Spacing Jig. NOTE It is acceptable if the Module marks may not be aligned to the Chassis. It is important that the Module Clamps apply pressure within the Module manufacturers allowable region of clamping/bolting. Tighten this set of Clamps first Torque to 12 ft.-lbs. Then Tighten this set of Clamps Torque to 12 ft.-lbs. Tip! The Module installation is Repetitive (install sequentially as shown) 1. Work sequentially, installing the Modules along rows. 2. Pull loose Chassis into alignment with marks on Modules. 3. Always use the Module Spacing Jig. 4. Always tighten each Module s Clamps before installing the nextin-line Module. 5. Always apply ballast to the completed row before moving on to the next row. Assembly Instructions, POWER XPRESS (Version 2, Rev A) 13
5 Placing Minimum Ballast (temporary ballast) As each Module is secured to its four supporting Chassis, the minimum of two ballast blocks per Chassis should be set in place. This ballast serves as an anchor, holding the previously secured Module and its Chassis in alignment and in place as northward Modules are installed. CAUTION This minimum ballast is for purposes of the installation process only. After the Deflectors are installed and without exception, ballast must be installed/applied per the job layout. Be absolutely certain that the concrete blocks meet the specified weights. Failure to do so could lead to a catastrophic structural failure and severe personal injury or death. Furthermore, failure to meet specifications voids the system warranty. 14 Assembly Instructions, POWER XPRESS (Version 2, Rev A)
6 Installing the Deflectors CAUTION Complete all wiring and connections before installing Deflectors. Deflector Clips (which retain the Deflectors) are designed for one time use only; they cannot be removed and re-used. If removed, they must be discarded and replaced with a new Deflector Clip. NOTE Deflectors are only used on Full Chassis; they are not used or required on End Chassis. All Deflectors overlap one another. Deflectors are locked in place via the Catch of the Chassis and secured with Deflector Clips. Alignment Holes Alignment Holes align with flanges as shown. Alignment Holes Look through the alignment holes and center the flanges within the holes. Alignment is critical to facilitate the installation of the Deflector Clips and to ensure proper overlap of one Deflector to another. CAUTION Be absolutely certain that Deflectors are properly locked into position using the Catch. Failure to do so could lead to a catastrophic structural failure and severe personal injury or death. Furthermore, failure to meet specifications voids the system warranty. Start by placing the bottom lip of the Deflector under Catch. Next, tilt the Deflector upward into position. Catch Assembly Instructions, POWER XPRESS (Version 2, Rev A) 15
6 Installing the Deflectors (continued) Deflector Clips pass through the two notches of the Deflectors and snap into mating notches of the Chassis Module Supports. Pay close attention to the mating of the Clips to the notches of the Chassis, being certain that there is full engagement and a secure lock is achieved CAUTION Deflector Clips (which retain the Deflectors) are designed for one time use only; they cannot be removed and re-used. If removed, they must be discarded and replaced with a new Deflector Clip. Deflector Clips CAUTION Be absolutely certain that Clips are securely locked into position with the Chassis notches. Failure to do so could lead to a catastrophic structural failure and severe personal injury or death. Furthermore, failure to meet specifications voids the system warranty. NOTE As an option, Deflectors and Clips may be screwed down by driving a screw through the hole in the Deflectors and Clip and into the Module Support. A 1/4-11 x 2 Tek Screw may be used. Consider this option to abate noise from wind gusts. The two Catches must fully engage and lock into the Notches Pilot hole is used to install an optional screw if wind noise abatement is a concern (see Note at left) Deflector Clip Notches 16 Assembly Instructions, POWER XPRESS (Version 2, Rev A)
Appendix A-1 Installing EPDM Strips on full and half Chassis (optional item, not on all asystems) Each Chassis has 2-slots for EPDM Strips End Chassis Full Chassis Top portion of EPDM must be pushed through the Slots to lock the EPDM in place. Push EPDM Strips into Slots Deflector Clip Assembly Instructions, POWER XPRESS (Version 2, Rev A) 17
Appendix A-2 5-Degree End Chassis (non-symetrical and used at row ends both east and west) Most all of the images in these instructions show main components from a 10-Degree system. For the most part, these images work just as well when installing a 5-Degree system. But one component - the 5-Degree End Chassis - needs to be clearly identified and its installation clarified. The 5-Degree End Chassis installs much like the 10-Degree End Chassis shown in Steps 4 & 5. It uses the same Module alignment marks as shown on page 8 to set its position on the Module, and its Module clamping system is identical to that in Step 3. Please note how this Chassis varies in its alignment relationship to the Modules. As can be seen in the bottom image to the right, the pans of this Chassis differ in their alignment (east to west) with their respective Modules while the Module Clamps positions are symmetrical. Only the Pans are offset. This Chassis configuration allows for full size ballast blocks while also eliminating the need for left and right symmetrical versions of the 5-Degree End Chassis. One version is utilized in both locations east or west. 5-Degree End Chassis Note Alignment of End Chassis Pan to Modules Varies from East to West 5-Degree End Chassis 18 Assembly Instructions, POWER XPRESS (Version 2, Rev A)
Appendix A-3 High Wind Ballast Tubes (optional item, only used when required by wind conditions) High Wind Ballast Tubes are installed between Full and/or End Chassis creating a structural support for additional ballast blocks. Tubes are held in place by the Ballast Blocks. No tools are needed to install them and o-rings are not used. O-rings are only used where they were factory installed on the Full Chassis. Tubes are installed into the existing holes of the N-S Frame Members in a similarly to the factory installed tubes of the Full Chassis. Refer to site specific layout drawing for areas of the array that require High Wind Ballast Tubes. Install the Tubes as noted. NOTE High Wind Ballast Tubes must be installed before the PV Modules are installed. High Wind Ballast Tubes High Wind Ballast Tubes Insert Tube into Chassis Installed Tube Assembly Instructions, POWER XPRESS (Version 2, Rev A) 19
Appendix A-4 Installing Brace Kits (optional item) The Brace Kit must be used when using the Module Frame as a structural component is not an option. (see module manufacturer for recommendations) NOTE Brace Kits must be installed before the PV Modules are installed. Brace Brace Brace 1/4 Flange Nut 1/4-20 x 3/8 Hex Bolt Torque to 10 ft.-lbs. 1/4 Flat Washer 20 Assembly Instructions, POWER XPRESS (Version 2, Rev A)
Appendix A-5 Grounding/Bonding Path Assembly Instructions, POWER XPRESS (Version 2, Rev A) 21
Appendix A-6 Compatible Modules - these modules meet the UL 2703 standard This racking system may be used to ground and/or mount a PV module complying with UL 1703 only when the specific module has been evaluated for grounding and/or mounting in compliance with the included instructions. Manufacturer Frame Thickness Model Canadian Solar 40 mm CS6P 250P, CS6P 255P, CS6P 260P, CS6P 260P SD, CS6P 265P, CS6P 265P SD, CS6P 270P Heliene 40 mm 60P MIM Kyocera 46 mm KU250 6BCA,KU255 6BCA, KU260 6BCA, KU265 6BCA 35 mm LG300N1C G3, LG305N1C G3, LG310N1C G3 LG 36 mm LG365N2W B3, LG375N2W-B3 40 mm LG320N1C G4, LG325N1C G4, LG 335N1C G4, LG340N1C G4 46 mm LG375N2W G4 REC Solar 35 mm REC265TP, REC270TP, REC275TP, REC280TP, REC285 38 mm REC240PE, REC245PE, REC250PE, REC255PE, REC260PE, REC265PE, REC270PE Silfab 38 mm SLA260M, SLA265M, SLA270M, SLA275M, SLA280M, SLA285M, SLA290M, SLA295M, SLA300M Solar World Suniva 31 mm SW280 31mm 33 mm 38 mm SW280, 285, 290, 295, 300 33 mm, SW 320 XL 33mm FR, SW 325 XL 33mm FR, SW 330 XL 33mm FR, SW 335 XL 33mm FR, SW 340 XL 33mm FR, SW 345 XL 33mm FR, SW 350 XL 33mm FR OPT 275 60 4-100, OPT 280 60 4-100, OPT 285 60 4-100, OPT 290 60 4-100, OPT 295 60 4-100, OPT 300 60 4-100 Sunpower 46 mm SPR 327NE WHT D, SPR 333NE WHT D, X21 335 BLK, X21 345 BLK Suntech 50 mm STP270 24/Vd, STP275 24/Vd, STP280 24/Vd, STP285 24/Vd, STP290 24/Vd, STP295 24/Vd, STP300 24/Vd, STP305 24/Vd Topoint Solar 35 mm JTM185 72M, JTM190 72M, JTM195 72M, JTM200 72M Trina 40 mm TSM 290PD14, TSM 295PD14, TSM 300PD14, TSM 305PD14, TSM 310PD14, TSM 315PD14, TSM 320PD14, TSM 325PD14 22 Assembly Instructions, POWER XPRESS (Version 2, Rev A)
Appendix A-7 Installing a WEEB-LUG 8.0 IMPORTANT Before installing verify with the lug manufacturer for any updates or revisions to these lug installation instructions. One of two mounting methods may be used defined here as Methods A and B. Lug is suitable for use with 14-6AWG solid or stranded copper conductor when tightened to 5ft-lbs. Mounting Screw Flat Washer Mounting Surface Lock Washer WEEB Washer Lug Mounting Screw Mounting Surface Serrated Flange Nut WEEB Washer Lug Hex Nut Mounting Method A Mounting Method B Cat No. Max OCPD (A) Min Profile (w x l) Mounting Surface Min Thick (in) Max Thick (in) Mtl Surface Prep Mounting Screw Size Tightening torque (lbs.-in) Mounting Hole Range Min (mm) Max (mm) WEEB-LUG-8.0 200 22mm x 20mm.06.25 AL Anodized.06.25 Steel Galvanized 5/16 M8 120 7.85mm 10mm Table 1: Mounting Surface Requirements IMPORTANT NOTES 1. Before installing verify with the lug manufacturer for any updates or revisions to these lug installation instructions. The instructions on this page only address the WEEB-LUG-8.0 as found within the manufacturers (Burndy) document number 50016572 Rev E. 2. The NEC section 690.43 states, Exposed non-current carrying metal parts of module frames, equipment, and conductor enclosures shall be grounded in accordance with 250.134 or 250.136 (A) regardless of voltage. 3. For Proper Equipment Grounding Conductor (EGC) and Overcurrent Protection Device (OCPD) sizing, refer to NEC sections 250.66, 250.122 and 250.166. Assembly Instructions, POWER XPRESS (Version 2, Rev A) 23
Albuquerque Office 1700 Louisiana Blvd., Suite 130 Albuquerque, NM 87110 Corporate Headquarters 660 Beta Drive Mayfield Village, OH 44143 Telephone: 800.260.3792 Fax: 505.889.3548 www.preformed.com E-mail: info@plpsolar.com 2017 Preformed Line Products PCN 022417-1 Version 2, Rev A SP3285-5