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APA TITAN DUO - User Manual

APA TITAN DUO
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Updated: April 2021
INSTALLATION MANUAL
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Summary

EQUIPMENT CHECKLIST

TOOLS REQUIRED

Lists essential tools for installation.

SAFETY EQUIPMENT (PPE)

Lists necessary personal protective equipment.

PARTS LIST

STRUCTURAL MEMBERS

Lists the main structural components of the racking system.

HARDWARE

Lists all fasteners, clamps, and other small parts.

SITE PREPARATION AND LAYOUT

SITE PREPARATION

Steps for preparing the installation site before construction begins.

SURVEYING

Procedures for surveying and staking row locations.

UTILITIES

Importance of marking utilities before starting construction.

INSTALLATION PROCEDURES

REVIEW & INSTALLATION PREPARATION

Understanding site layout, surroundings, and procedures.

STRINGING

Process for setting up string lines for alignment.

MEASURING

Techniques for accurate East-West measurements and alignment.

SITE CONDITIONS AND ADJUSTMENTS

FLAT SITES

Methods for driving piles on flat terrain for straight alignment.

UNEVEN GROUNG

Techniques for setting posts on rolling or uneven terrain.

OBSTRUCTIONS

How to handle impassable objects during post placement.

HEIGHT ADJUSTMENTS

Procedures for correcting post heights after installation.

PILE INSTALLATION

PILE INSTALLATION

Step-by-step guide for driving piles using string lines.

ALTERNATE PILE INSTALLATION

Method for installing piles in rocky or bedrock conditions.

ANCHOR POST-TO-PILE CONNECTION

ANCHOR POST-TO-PILE

Attaching anchor posts to the installed piles.

CHORD AND BRACE ASSEMBLY

N;S CHORD-TO-REAR POST

Securing the N/S chord to the rear anchor post.

KNEE BRACE & CHORD-TO-FRONT POST

Attaching knee braces and N/S chords to front posts.

KNEE BRACE-TO-BRACE CLAMP

Installing the brace clamp for connecting knee braces.

ROLL BRACKET AND PURLIN ASSEMBLY

ROLL BRACKET-TO-N;S CHORD

Attaching roll brackets to the N/S chord.

ZEE PURLIN STAGING

Positioning and staging zee purlins on the N/S chord.

PURLIN CONNECTIONS

ZEE PURLINS TO ROLL BRACKET

Securing zee purlins to the roll bracket assembly.

ZEE PURLINS-TO-N;S CHORD

Fastening zee purlins to the N/S chord.

TRANSVERSE BRACE AND PURLIN SPLICE

TRANSVERSE BRACE-TO-ZEE PURLIN

Installing transverse braces to zee purlins for stability.

ZEE PURLIN-TO-ZEE PURlin (SPLICE)

Splicing zee purlins together for structural integrity.

PANEL CLAMP AND INSTALLATION

GRAVITY CLIP PREINSTALLATION

Installing gravity clip assemblies on zee purlins.

PANEL INSTALLATION

Initial steps for staging and installing PV modules.

CABLE BRACING

CABLE BRACE-TO-ANCHOR POST

Installing cable braces to anchor posts for stability.

PRO TIPS

INSTALLATION ACCURACY TIPS

Advice on using string lines, tapes, and alignment tools for precision.

SITE & TOPOGRAPHY ADVICE

Tips for handling obstructions, uneven ground, and pile placement.

INSTALLATION EFFICIENCY TIPS

Techniques for easier and faster installation of components.

OPERATION & MAINTENANCE

BOLTED CONNECTIONS

Annual inspection and tightening of bolted connections.

SOLAR PANEL CLAMPS

Annual inspection and tightening of panel clamps.

GALVANIZE COATING

Inspecting and maintaining galvanized coating for corrosion protection.

CROSS BRACING CABLE WIRE

Annual inspection of cable bracing for tightness.

SYSTEM DAMAGE

Inspecting for and addressing any damage to the racking system.

GENERAL OPERATION

General advice for maintaining the system and its lifespan.

Overview

The provided document is an installation manual for the TITAN DUO Solar Racking System by APA Solar Racking. This system is designed for ground-mounted solar panel installations, offering a robust and adaptable solution for various site conditions.

Function Description

The TITAN DUO Solar Racking System serves as the structural support for photovoltaic (PV) modules, elevating them off the ground and orienting them to maximize solar energy capture. It is a dual-post, ground-mount system, meaning it utilizes two anchor posts per support point (a "short" front/South post and a "long" rear/North post) to create a stable and adjustable framework. The system is designed to accommodate multiple rows of solar panels, with components like N/S chords, EW Zee purlins, roll brackets, and various braces working together to form a rigid structure. The installation process emphasizes precision in surveying, pile installation, and component assembly to ensure the array is plumb, level, and correctly aligned with the terrain and customer plans. The system's design allows for adjustments to accommodate uneven ground and obstructions, making it versatile for different site topographies.

Important Technical Specifications

While specific numerical technical specifications like material grades, exact dimensions, or load capacities are not explicitly detailed in the provided pages, the manual highlights several key aspects of the system's construction and components:

  • Structural Members: The system comprises several key structural components:
    • Roll Bracket Assembly: Includes push-in studs (2x 3/8-16x1.0" and 1x 1/2-13x1.0") for attaching to the N/S chord and supporting the Zee purlins.
    • NS Chord: The main longitudinal support member, connecting to the anchor posts.
    • EW Zee Purlin: The transverse members that directly support the solar panels. These come in different lengths and hole patterns.
    • Knee Brace: Provides lateral stability, connecting the N/S chord and the front anchor post.
    • Transverse Brace: Minimizes transverse movement (racking) and keeps the rack square, connecting Zee purlins.
    • Screw Pile: The foundation element driven into the ground.
    • Anchor Post: The vertical posts (short for front/South, long for rear/North) that connect the screw piles to the racking structure.
    • Cable Brace: Used to limit movement and reduce fatigue, connecting anchor posts.
  • Hardware: A variety of fasteners are used, including:
    • Serrated Flange Nuts (3/8-16, 1/2-13, M8x1.25)
    • Serrated Flange Bolts (1/2-13x1.0", 1/2-13x3.5", M8x1.25 25mm, M8x1.25 70mm)
    • Hex Bolts (M8x1.25 25mm, M8x1.25 70mm, M16x2.0 30mm)
    • Lock Washers (M8)
    • End Clamp Assembly (with hex bolt, lock washer, and clamp sized for panel)
    • Midclamp Assembly (with hex bolt, lock washer, mid clamp, spring, and serrated flange nut) – specifically mentions "Weeb Washer" for outer Zee purlins and "Gravity Clips" for center Zee purlins.
    • Knee Brace Clamp
    • Cable Clamp Assembly (with cable clamp, 5/16 hex nut, 5/16 carriage bolt)
  • Foundation: Screw piles are the primary foundation, with an alternative method for rocky terrain involving pilot drilling and backfilling with stone. The top of the screw pile is typically 6" from the ground.
  • Adjustability: The system allows for height adjustments of anchor posts and accommodates variations in terrain. Bolts are initially fastened loosely to allow for adjustments before final tightening.
  • Orientation: Components are designed for specific orientations (e.g., N/S chord on the West side of the post, Zee purlins with slotted side facing up and towards the front of the rack, bolt heads facing down for wire tray clearance).

Usage Features

  • Adaptability to Terrain: The TITAN DUO system is designed to follow terrain, with provisions for intermediate piles/stakes and string lines to ensure smooth flow over hills and valleys. Height adjustments can be made to individual posts to conform to the landscape.
  • Obstruction Management: If an impassable object is encountered, the system allows for relocation of posts (6-8" East or West) and drilling new holes in the EW Zee purlins. Mating posts must be moved in tandem.
  • Modular Design: The system is built step-by-step, with components like roll brackets, Zee purlins, and braces being installed sequentially. This modularity likely aids in efficient assembly and scalability.
  • Panel Installation: PV modules are staged by hanging them on lower hooks of preinstalled gravity clip assemblies. The system uses end clamps and midclamps (with gravity clips for center purlins and weeb washers for outer purlins) to secure the panels.
  • Wire Management: Bolts are installed facing down to keep the wire tray clear, suggesting consideration for cable routing.
  • Installation Best Practices (Pro-Tips): The manual provides numerous "Pro-Tips" for installers, including:
    • Installing a test row first to understand tolerances and adjustments.
    • Using two sets of string lines for pile installation (one for height, one for embedment).
    • Using a steel tape for measurements to avoid stretching errors.
    • Marking every pile location in extreme topography.
    • Using grip clamps for post transitions and brace clamp installation.
    • Aligning keyhole slots with a spud wrench during Zee purlin installation.
    • Tightening bottom nuts of module clamps slightly during staging to free up an installer's hand.
    • Using a T-square or board to align modules for squareness.
    • Crucially, it warns against staging an entire row of modules or leaving untightened clamps to prevent wind damage.

Maintenance Features

The manual outlines essential Operation & Maintenance (O&M) requirements to ensure the design life and warranty of the TITAN solar racking system. These procedures should be performed annually:

  • Bolted Connections Inspection: Visually inspect all bolted connections (especially at the beginning, middle, and end of each row) to ensure components are properly joined and no movement has occurred. Re-tighten loose hardware to specified torques.
  • Solar Panel Clamps Inspection: Annually inspect clamps to ensure modules are properly secured. Re-tighten loose clamps to specified torques.
  • Galvanize Coating Inspection: Inspect for any areas of corrosion or rust. Repair affected areas by cleaning and applying cold galvanizing compound. The manual notes that corrosion on cut, slit, and sheared edges is normal and does not affect structural integrity.
  • Copper Isolation: Emphasizes that copper should be isolated from galvanized coating to prevent expedited corrosion.
  • Cross Bracing Cable Wire Inspection: If applicable, visually inspect bracing to ensure it has not become loose. Cables should be taut for motion limiting but not tensioned like trusses.
  • System Damage Inspection: Inspect for damage from mowing equipment, maintenance equipment, falling trees/branches, storm damage, system lean, or soil erosion. Damaged or deformed components should be replaced or repaired.
  • General Operation & Site Management:
    • Maintain vegetation management to keep it off the racking system and modules.
    • Ensure cleaning solutions, weed killers, or other chemicals used are not corrosive to galvanized or stainless steels.
    • Check electrical wiring for proper management and protection.
    • Log inspections and corrective actions for future reference.

APA TITAN DUO Specifications

General IconGeneral
BrandAPA
ModelTITAN DUO
CategorySolar panel
LanguageEnglish