CK- STEEL SOLAR
CARPORT GAZEBO
INSTALLATION MANUAL
VERSION: 0225VO2

CK Signature Solar 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 D ESCRIPTION

The CK-Steel Carport/Gazebo is a robust solar carport that can accommodate a wide range of panel sizes, with a max (North/South or Up/Down) span of 270”. 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 professional 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, safety 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 once a year ensuring all connections are secure, and after any major storm or weather occurrence. Tighten all bolts according to torque specs.
3. If the columns of the structure are hit, you must replace the columns of the structure immediately.3.

WARNING
If any structural component of the system to include the column, beam, base plate, or rail are damaged they must be replaced immediately.

MEASUREMENT NOTE

All measurements have been converted from MM to Inches. The accuracy of measurement can vary slightly from mm to inches. All measurements are available in MM for detailed accuracy. The most critical measurement required is the Base Plate. Please review the Construction Drawings for the Base Plate and Base Plate locations prior to installation.

REQUIRED INSTALLATION TOOLS

MAIN COMPONENTS

NOTE
Customer needs to source materials for footings based on structural engineer specifications.
Overview
The following is a diagram that list the mian components of the CK- Carport System.

COMPONENTS LIST

Structure
CK-ZEM-CP3-5
COLUMNS
CK-001-016-014
BEAMS
GT-001-016-014
Base ‘Plate’
CK-GT-001-016-805
GT-001-016-805
Column/Beam
Adapters
Beam
CK-GT-001-016-014
Column
CK-001-016-014| Front Columns| 2
Rear Columns| 2
Base Plate| 4
Support Beam| 2
Top Column Adapter| 4
Lower Horizontal Beam| 2
Diagonal Brace| 4
LowBeam & Diagonal Brace Adapter| 4
HDG Bolt M12140| 20
HDG Bolt M14155| 30
HDG Nut M12| 20
HDG Nut M14| 30
HDGWasher M12| 40
HDGWasher M14| 58
HDG Spring Washer M12| 20
HDG Spring Washer M14| 30
2| | M Rail
CK-ZEM-010-5760| MWater-proof Rail| 14
Self Taping Screw| 60
3| | Water Channel
CK-009-1062| Water Channel| 18
4| | Water Prooof Strip
CK-IP-160-1133| Water Proof Rubber|
5| | Purlin ‘C’ Channel
CK-PL-C140-001-016-
6000| C-Channel 220 7/16”| 6
C-Channel 62 16/16”| 6
6| | L Angle Support| 224³/8”| 2
7| | C RAIL
Purlin Fix Kit
CK-PL-GT001-016-14| Purlin Fixed Kit 12| 12
HDG Bolt M1040 40| 40
HDG Bolt M12140 20| 20
HDG Nut M10 40| 40
HDG Nut M12 20| 20
HDGWasher M10 80| 80
HDGWasher M12 40| 40
HDG Spring Washer M10 40| 40
HDG Spring Washer M12 20| 20
8| | Mid Clamp
CK-782-4-60-Q
BRACKET#

CK-A845-801| 35mm Mid Clamp 40| 40

845 Share Plate 40| 40
M Grounding Plate 40| 40
Self Tapping Screw 48| 48
SS304 Bolt M8*45 24| 24
SS304 Spring Washer M8 24| 24
9| | End Clamp
CK-737-3-60-Q
BRACKET#

CK-1845-801| 35mm End Clamp 16| 16

845 Share Plate 16| 16
M Grounding Plate 16| 16
Self Tapping Screw 24| 24
SS304 Bolt M845 12| 12
SS304 Spring Washer M8 12| 12
10| | Grounding Lug
CK-GTC-R2| Grounding lug- weeb lug 8.0 6| 6
SS304 outer hex bolt 1/4″ 0.6” 6| 6
SS304 inner hex bolt M820 6| 6
SS304 inner hex bolt M820| 6

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.

2. 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. Products Name| Quantity
   ---|---
   Base| 4
   M12 Nut Kits (1 flat washer + 1 spring washer + 1 nut)| 4

3. Fix Adapter
   A . Fix Low Beam/Diagonal Brace Adapter to Front & Rear Columns
   B1. Attach C-Rail Fix Kit to Support Beam
   B2. Attach Top Column Adapter to Support Beam
   Front Column: 111”
   Rear Column: 126 7/16”
   Low Beam/Diagonal Brace Adapter: 16 ½”
   Top Column Adapter: 10 3/16
   Support Beams: 228 5/16

4. Connect Columns
   Attach Columns to base plate Products Name| Quantity
   ---|---
   Front Columns — 111”| 2
   Rear Columns —126 ½”| 2
   M10*120mm Bolt Kits (1 flat washer+ 1 spring washer+ 1 nut)| 16

5. Connect Beams
   Connect Lower Horizontal Beam to front and rear Columns
   Connect Support Beam between front and rear columns on top
   Connect Diagonal Brace between Support Beam and Column Products Name| Quantity
   ---|---
   Lower Horizontal Beam 168 ¹/16| 2
   Support Beam 228 5/16| 2
   Diagonal Brace 47 ³/16”| 4

6. Fix C Rail
   Combine C-Rails with C-Rail Splice Kit
   Use C-Rail Fix Kit to connect C-rails to Support Beam
   Use M616mm Bolt Kits (1 flat washer + 1 Spring Washer + 1 Nut)
   Use M625mm Bolt Kits (1 flat washer + 1 Spring Washer + 1 Nut) Products Name| Quantity
   ---|---
   C Rail — 220 ½”| 6
   C-Rail Fix Kit| 24
   C-Rail 62 16/16| 6
   M1040mm Bolt Kits (1 flat washer+ 1 spring washer+ 1 nut)| 12
   M12140mm Bolt Kits (1 flat washer+ 1 spring washer+ 1 nut)| 12

*When spliced, total length of C-Rail is 283 ½”

7. Pre-assemble clamps on M Rail
   Overlap 2qty M-Rails, attach the 2 M-Rails together with 2 M6316, ensure overlap is facing toward low slope side of installation, ensuring water flow over top of M-rails connection point.
   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. Products Name| Quantity
   ---|---
   M Rails—142 ¹/8”| 14
   Share Plates| 16
   Mid Clamps| 72
   End Clamps| 56
   M6.316| 40

8. Fix M Rail
   Use M6.325 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.
   Please Review Math Calculation in Appendix Products Name| Quantity
   ---|---
   M Rails 142 ¹/8”| 14
   M6.316| 72

9. 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 Products Name| Quantity**
   ---|---
   Modules| 18 or 24
   Rubber| 1 Roll
   Water channel — 1061| 12 or 18

10. Grounding- Lug and Wiring
    Install grounding lug at end of C-Rail in pre-drilled hole, ensure that all paint and any debris is removed from bonding site to achieve bonding connection. Attach the ground lug with a stainless steel nut then cross 8.4mm2 or greater than or equal to 8AWG copper wire through all 5 grounding lugs (fixed by M8*20 inner hex bolt), finally connect copper wire to the ground. The grounding lug completes a grounding function when fastened tight to connect all 5 C Rails and copper wire.Electrical Characteristics of AWGCopper 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

11. Final Check
    Check that all bolts are fastened, and that all components are in their correct position and location.
    Check and adjust all components within the structure as needed.

12. 12. Hide Footing (Optional)
    Cladding of 4 bases is an option with engineer approval.
    Cement grade: not less than C30.

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

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