Solar Mounting System Installation Guide RBI Solar One-Piece Ground Mount Solution GM-GS Ballasted Ground Mount System RBI Solar 1292 Logan Circle NW Atlanta, GA 30318 513-618-7240 info@rbisolar.com
OVERVIEW The RBI Solar One-Piece Ground Mount Solution GM-GS product line is a one-piece ballasted PV mounting system for ground-mount applications available in a 10 tilt. Most projects require minimal ballast. Made from 100% recycled high molecular weight polyethylene (HMWPE), this system transports easily and sets up quickly. The RBI Solar One-Piece Ground Mount Solution GM-GS system accommodates all 72-cell aluminum-framed modules. A RBI Solar drill jig can be purchased separately to make the module mounting hole drilling process quick and easy. Mounting holes or drill targets can be applied during the manufacturing process for an additional cost. Please read this guide carefully before starting installation. Always follow proper safety precautions. Be sure to check with local building codes to ensure compliance. Check for the latest version of the installation guide at www.rbisolar.com. IMPORTANT INSTALLATION DETAILS Project Layout Always use the Project Details provided by RBI Solar. Always contact RBI Solar if the Project Details needs to be changed so a new set can be quickly developed. Site Conditions Always check the Coefficient of Friction (COF) and compare it to the value in the Project Details. The RBI Solar GM-GS Friction Coefficient Test Procedure can be found on our company website. If the actual value is lower that the value on the Project Details, contact RBI Solar before installation begins. This system is designed to be installed on slopes no greater than 5. For sloped sites, leveling or terracing the site will be required. Never install a system on windy days. Materials Always use the correct fasteners supplied by RBI Solar and never use fasteners purchased anywhere else. Contact RBI Solar if additional fasteners are needed Take a sampling of weight measurements as block weight vary by manufacturer and location. Assembly Sequence Always complete Assembly Steps 1 and 2 for an array within one day. Never leave the job without all of the ballast blocks placed in the bases. Always follow the assembly steps in order. Always place all ballast blocks in a base before drilling the base. Always check that the drill fixture is still in proper alignment before drilling all holes in the base. Warranty Installation instructions and applicable building code must be followed or product warranty is void. RBI Solar will not be responsible for any loss and/or liable for any claim resulting from installations that are not in accordance with installation guide instructions and/or applicable building code. RBI Soalr Solar Mounting Systems 5513 Vine Street, Cincinnati, OH 45217 513-242-2051 www.rbisolar.com Always measure ballast blocks in their dry state. 2
SYSTEM COMPONETNS Base Bag A: Base Connection Hardware Bag B: Module Connection Hardware 10 Tilt A1 T-bolt (20mm) B1 Module Bolt B2 T-Washer A2 Flat Washer B3 Large Washer A3 Nylon-coated B4 Push-on Retainer Flange Nut B5 Flange Nut B6 Small Washer REQUIRED TOOLS Cordless Drill 7/16 Socket Driver 3/8 Split-point drill bit Tongue & Groove Pliers ADDITIONAL REQUIREMENTS (offered by RBI Solar) RBI Solar GM-GS Assembly Tool Kit Right-angled drive attachment 7/16 drive socket & adapter Module Jumper Used for module-to-module grounding in the east-west direction Can be used on multiple projects Drill Jig Adjustable jig allowing to proper hole placement Wire Management Ties Used for PV cable wire management See Drill Jig Instructions for assembly Can be used on multiple projects OPTIONAL REQUIREMENTS (not offered by RBI Solar) Solid Concrete Blocks Suggest 4x8x16, weights vary by location and supplier Module Grounding Lug Recommend TYCO 1954381 series Used to ground rows within an array 3
INSTALLATION Step 1. Connect Bases The installation site must be flat and clear of debris. Preventative weed control should be addressed prior to installation. A3 A2 Starting on the west side, place the first base on the site. Place the next adjacent base on the site with the west end overlapping the east end of the first base. The overlap will set into the groove on the east end of the base lining up the embossments for the interconnection holes. Using the components from Bag A, fasten the bases together using A1 the T-bolt, A2 flat washer, and A3 nylon-coated flange nut at both interconnection locations. Tighten to 8 ft-lbs. A1 Repeat the steps for the entire row. For the next row, space it away from the first row as defined in the Project Details. Repeat the steps above to position all bases within one array. Array with sample east-west connection Step 2. Load Ballast Using the Project Layout as a guide, add ballast blocks to each of the bases. 4
INSTALLATION Step 3. Drill Base Place drill jig on base and drill four 3/8 holes in the base through the appropriate holes in the jig. Refer to RBI Solar Drill Jig Guide for setting jig. Important: Never drill holes before all ballast blocks are added to the base. B4 B6 B2 B1 Step 4. Fasten Parts to Module Flip the module face side down. Find the mounting holes or slots in the bottom of the modules. Using the fasteners in Bag B, install the B1 bolts, B2 T-washers, B6 small washers, and B4 push-on retainers and as shown in the image. Important: For modules that will be placed on the end of a row, a TYCO Lug (or similar grounding lug) needs to be installed for homewire grounding to connect each of the rows within an array. See Step 6 for additional information. B3 B5 B3 B5 TYCO 1954381 Series (Sol Klip) Step 5. Fasten Module to Base Set the module assembly onto the base with the four screw studs in line with the four holes in the base. Reaching under the lip of the RBI Solar GM-GS at one of the connection points, slip a B3 large washer onto the B1 bolt and hand start the B5 flange nuts. Repeat for the remaining three bolts. 5
INSTALLATION Hex Bit Adapter 7/16 Socket Driver Assemble the RBI Solar GM-GS Assembly Tool Kit as shown in the image. Cordless Drill Right-angled Drive Attachment Reaching below the lip of the RBI Solar GM-GS base, use the assembled tool tighten all nuts to 8 ft-lbs. Repeat these steps for all modules. Module Jumper Step 6. Module Grounding Slide the Module Jumper onto the lip of adjacent module flanges to bond the modules together in the east-west direction. Use Tonge-and-groove pliers for assistance with attachement. Attach a copper wire to the TYCO Lug (or similar grounding lug) along the ends of each row for home run groundwire. Home Run Groundwire TYCO Lug Installation is complete. If you have any questions during installation, please contact the RBI Solar team. 6
INSTALLATION Microinverter Mounting The RBI Solar GM-GS is manufactured with drill targets for Microinverter mounting. Drill one or two 3/8 holes in the center rib of the RBI c Solar GM-GS that line up with the mounting slots on b the microinverter being used. a Using the RBI Solar GM-GS Microinverter Mounting Kits, fasten the microinverter to each base. See component list below. RBI Solar GM-GS Microinverter Mounting Kit Description Qty a T-bolt 15 b Washer 15 c Flange Nut 15 RBI Solar GM-GS Wire Management The RBI Solar GM-GS is also manufactured with drill targets for wire management solutions. Drill one 1/4 hole in the drill targets located on the east and west sides of the product as needed. Push the RBI Solar GM-GS Wire Management Tie into the hole and wrap PV/trunk cables as shown. 7