CK-ZEM Steel Solar Carport Gazebo
Instruction Manual

CK-ZEM Steel Solar Carport Gazebo

Always use the most recent version of the installation manual before installing your Carport/Gazebo. The installation Manual is subject to change without notice. Please consult with CHIKOUSA to ensure you are utilizing the latest Install Manual.

BRIEF DESCRIPTION

CK-ZEM Steel Solar Carport/Gazebo is a robust double carport that can accommodate 3 panels in portrait, 6 across, totaling 18 panels. This structure can be installed with a 2-3 person crew, without the Need of any heavy duty tools. The installation should always be completed by trained professionals and/or qualified individuals, who have been adequately instructed and trained about the tasks involved with the installation, including the usage of protective devices, protective measures, relevant provisions, accident prevention regulations, and local operating site conditions and have proven competence in all areas of the installation.
Please read carefully this installation manual and all other applicable documents before starting your installation. Please contact CHIKO with any questions that you may have.

MAINTENANCE

1. When signs of rust appear, or when the paint is peeled or removed, you must take steps to remove the rust and paint the affected areas.
2.  You must check the bolts are secured once a year. Tighten according to torque specs.
3. If the columns of the structure are hit, you must replace the columns of the structure immediately.

WARNING
If any structural component of the system to include the column, beam, base plate, or rail are damaged they must be replaced immediately.
REQUIRED TOOLS MAIN COMPONENTS NOTE
Customer needs to source materials for footings based on structural engineer specifications.

MAIN COMPONENTS

Overview/Diagram
The following is a diagram that list the main components of the CK-ZEM Carport System

COMPONENTS LIST

SECT.| CAT| Picture| Description PART#| Details| QTY
---|---|---|---|---|---
1, 2,3,
4,5| 1| | Carport Support
Structure CK-ZEM-CP3-5 COLUMNS
CK-001-016-014 BEAMS CKGT-001-016-014 Base ‘Plate’CK- GT-001-016-805 Column/Beam  Adapters Beam
CK-GT-001-016-014
Column CK-001-016-014| 1.1| Front Columns| 2
1.2| Rear Columns| 2
1.3| Base Plate| 4
1.4| Beam| 2
1.5| Beam Adapter| 4
1.6| Strengthen Beam 1| 2
1.7| Strengthen Beam 2| 1
1.8| Strengthen Adapter| 6
1.9| HDG Bolt M12140| 20
1.1| HDG Bolt M14155| 30
1.11| HDG Nut M12| 20
1.12| HDG Nut M14| 30
1.13| HDG Washer M12| 40
1.14| HDG Washer M14| 58
1.15| HDG Spring Washer M12| 20
1.16| HDG Spring Washer M14| 30
8| 2| | M Rail  CK- ZEM-010-5760| 2.1| M Water-proof Rail| 6
2.2| Self Taping Screw| 60
9| 3| | Water Channel
CK-ZEM-009-1062| 3| Water Channel| 10
9| 3| | Water
Proof Strip
CK-IP-160-1133| 3| Water Proof Rubber| 10
6| 4| | Purlin ‘C’ Channel
CK-PL- C140-001-016-811-600 0| 4|  Purlin C CHANNEL| 5
SECT| CAT| Picture| Description Part#| Details| QTY
---|---|---|---|---|---
1| 4| |   C RAIL Purlin Fix Kit CK-PL- GT001-016-14| 4.1| Purlin Fix Kit| 10
4.2| HDG Bolt M1040| 40
4.3| HDG Bolt M12140| 20
4.4| HDG Nut M10| 40
4.5| HDG Nut M12| 20
4.6| HDG Washer M10| 80
4.7| HDG Washer M12| 40
4.8| HDG Spring Washer M10| 40
4.9| HDG Spring Washer M12| 20
8,
9| 5| | Mid Clamp CK-782-4-60-Q BRACKET #

CK-A845-801| 5.1| 35mm Mid Clamp| 24

5.2| 845 Share Plate| 24
5.3| M Grounding Plate| 24
5.4| Self Taping Screw| 48
5.5| SS304 Bolt M8*45| 24
5.6| SS304 Spring Washer M8| 24
8,
9| 5| | End Clamp CK-737-3-60-Q BRACKET #

CK-A845-801| 5.7| 35mm End Clamp| 12

5.8| 845 Share Plate| 12
5.9| M Grounding Plate| 12
5.1| Self Taping Screw| 24
5.11| SS304 Bolt M845| 12
5.12| SS304 Spring Washer M8| 12
10| 6| | Grounding Lug CK-GTC-R2| 6.1| Grounding lug – weeb lug 8.0| 1
6.2| SS304 outer hex bolt 1/4″ 0.6”| 1
6.3| SS304 inner hex bolt M820| 1
6.4| SS304 inner hex bolt M820| 1

INSTALLATION STEPS

1. Build Base
Solution A, Build base

• Mark footer location according to the diagram. Verify all angles are square.
• Dig footers and make base with anchor bolts according to site conditions and system specifications and based on your structural engineer instructions for foundations requirements.
• If the ground is unlevel, ensure that all footer placements are level and at the same height regardless of the terrain elevation. Never install the structure tilted, the columns must always be straight.
• The structure’s foundations should be calculated taking into account site conditions, soil type, seismic conditions, maximum wind and snow loads for the site location and the product mechanical loading specifications. In some cases, a geotechnical study is required.
• Please consult with your local structural engineer.
• In areas subject to freezing, footer depths may have to increase to resist freeze heave. Always consult a structural engineer to confirm footer depth and dimension.

Solution B, Concrete anchors

• Concrete anchors can be utilized if approved by a structural engineer.

Install Base Plates
Slide the column base plate over the concrete anchors and secure them. If you are using leveling nuts to level the column base plate. Correct any shifting if needed and repeat for the other three column base plates. Fill the gap between the base plate and the footing with Dry-pack non-shrink grout.
Tip: The distance between the front and rear column conform with drawing.

Fix Adapter

• A . Fix strengthen adapters on front & rear columns
• B1. Fix beam adapters on main beam – 5400mm
• B2. Fix purlin fix kit to main beam – 5400mm

Connect Columns
Attach Columns to base plate-if concrete anchors, use corresponding Anchor Bolts

Connect Beams

• Connect beam 3910mm between front and rear columns
• Connect beam 5410mm between 2 rear columns
• Connect main beam 5400 mm between front and rear columns on top

Fix C Rail

• Use purlin fix kit to connect C rail 5745mm to main beam 5400mm
• Use M10*40mm Bolt Kits (1 flat washer + 1 spring washer + 1 nut) Connect to C Rail
• Use M12*140mm Bolt Kits (1 flat washer + 1 spring washer + 1 nut) Connect to main beam

Pre-assemble clamps on M Rail

• Pre-fix share plate to M rail
• Connect mid clamps to share plate
• Please check L1/L2/L3/L4 before fixing

TIP: Place 2 M-Rails in parallel on a flat level surface, then lay 3 panels in portrait on top of The M-Rails, ensuring proper spacing, then mark your share plate locations. Use these Measurements to install the remaining share plates on the remaining M-Rails.
For Mid Clamp and End Clam Installation: M8 Torque: 15~20N.m

Fix M Rail

•  Use M6.3*25 self tapping screw to fix M rail to C Rail
• With end clamps on the side M Rails
• With mid clamps on the inner M Rails
• Please check the L measurement before attaching

TIP: This is a critical step; if possible lay 7qty M-Rails down on flat level surface; place 6 panels across these M-Rails in Portrait configuration, ensure rails and panels are square; take measurement to confirm your starting M-Rail attachment location.

Install Solar Panels

• For waterproofing stick rubber molding to exterior of module frame but only where the frames are adjacent to other module frames or on all interior seams
• Install water channel (1061mm) where 2 panels meet under the module frame

Grounding- Lug and Wiring
(END at either end of row). Install grounding lug at end of-Rail in pre- drilled hole, ensure that all paint and any debris unremoved from bonding site to achieve bonding connection. Attach the ground lug with stainless steel, nut then cross 8.4mm2 or greater than or equal to8AWG copper wire through all 5grounding lugs (fixed byM8*20 inner hex bolt), finally connect copper wire to the ground. The grounding lug completes grounding function when fastened tight to connect all 5CRails and copper wire. Then run copper wire, attached to the column, and down into the ground, attaching to ground rod or other ground. Electrical Characteristics of AWG Copper Wire

AWG| Diameter [inches]| Diameter [mm]| Resistance [Ohm / 1000ft.]| Resistance [Ohm / km]| Max Current[Amperes]| Max Frequency for 100% skin depth
---|---|---|---|---|---|---
6| 0.162| 4.1148| 0.3951| 1.295928| 37| 1100 Hz
7| 0.1443| 3.66522| 0.4982| 1.634096| 30| 1300 Hz
8| 0.1285| 3.2639| 0.6282| 2.060496| 24| 1650 Hz
9| 0.1144| 2.90576| 0.7921| 2.598088| 19| 2050 Hz
10| 0.1019| 2.58826| 0.9989| 3.276392| 15| 2600 Hz

Grounding – Lug and Wiring Diagram

Final Check

• Check all bolts are fastened, all components are in right position
• Check and adjust the entire structure

Hide Footing (Optional- not applicable if Concrete Anchor)

• Cement cladding for 4 bases, Cladding Size: 300mm300mm300mm. Cement grade: not less than C30.

WORLDLEADING
MANUFACTURE

Tel _: 1-800-948-5390
Email : info@chikousa.com
www.chikousa.com
101 East Baseline Road
Buckeye, AZ 85326

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