CK- | STEEL SOLAR CARPORT | GAZEBO 3-CAR PREMIER
STEEL SOLAR CARPORT | GAZEBO
INSTALLATION MANUAL
VERSION: 03.19.23 VO2

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

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.

FOOTER WARNING **

**

Anyone who plans to dig should call 811 or visit their state’s 811 center’s website a few business days before digging to request that the approximate location of buried utilities be marked with paint or flags so that you don’t unintentionally dig into an underground utility line.

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 placement location. 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 lists the main components of the CK- Carport System.

|
---|---
|
CAT| Picture| Description Part| Details| QTY
---|---|---|---|---
1| | Carport Support
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| 3
Rear Columns| 3
Base Plate| 6
Support Beam| 3
Top Column Adapter| 6
Lower Horizontal Beam| 3
Diagonal Brace| 6
Low Beam & Diagonal Brace Adapt| 6
HDG Bolt M1035| 168
HDG Bolt M16180| 158
HDG Nut M10| 168
HDG Nut M16| 156
HDG Washer M10| 168
HDG Washer M16| 156
HDG Spring Washer M10| 336
HDG Spring Washer M16| 312
2| | M Rail
CK-ZEM-010-5760| M Water-proof Rail| 20
Self Tapping Screw| 200
3| | Water Channel
CK-009-1062| Water Channel| 27
4| | Water Prooof Strip
CK-IP-160-1133| Water Proof Rubber|
5| | Purlin ‘C’ Channel
CK-PL-C140-001-0166000| C-Channel 215 1/16″| 6
C-Channel 204 3/4″| 6
6| | L Angle Support| 224 3/8″| 3
7| | C RAIL
Purlin Fix Kit
CK-PL-GT001-016-14| Purlin Fixed Kit| 18
HDG Bolt M1035| 72
HDG Bolt M16140| 36
HDG Nut M10| 72
HDG Nut M16| 36
HDG Washer M10| 144
HDG Washer M16| 72
HDG Spring Washer M10| 72
HDG Spring Washer M16| 36
8| | Mid Clamp
CK-782-4-60-Q
BRACKET #

CK-A845-801| 35mm Mid Clamp| 64

845 Share Plate| 64
M Grounding Plate| 64
Self Tapping Screw| 256
SS304 Bolt M8*45| 64
SS304 Spring Washer M8| 64
9| | End Clamp
CK-737-3-60-Q
BRACKET #

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

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

INSTALLATION STEPS

1. Build Base
Solution A, Build base

• Mark footer location according to the diagram. Verify all angles are square (See Attached Planset).

• 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.

• Verify the distance between the front and rear column conform with the attached planset.

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

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

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 M10*16mm Bolt Kits (1 flat washer + 1 Spring Washer + 1 Nut)
• Use M10*25mm Bolt Kits (1 flat washer + 1 Spring Washer + 1 Nut)

*When spliced, total length of C-Rail is 419 13/16

7. Pre-assemble clamps on M Rail
Overlap 2qty M-Rails, attach the 2 M-Rails together with 2 M6*16, ensure overlap is facing toward low slope side of installation, ensuring water flow over top of M-rails connection point. Apply waterproof adhesive at seam where 2qty M-rails overlap after they have been mechanically attached.

• 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 or 4 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.

8. 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: If possible lay M-Rails on flat level surface, place panels across M-Rails in portrait configuration, ensure rails and panels are square; take measurement to confirm starting M-Rail location.

Please Review Math Calculation in Appendix

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 where 2 panels meet under the module frame

10. Grounding- Lug and Wiring
Install grounding lug at end of C-Rail on side of array that is most optimal for wire management.
Ensure that all paint and any debris is removed from bonding site to achieve proper bonding connection. Attach each ground lug with a stainless steel nut then cross 8.4mm2 or greater than or equal to 8AWG copper wire through all 6 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 6 C Rails and copper wire.

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

#8 AWG or Greater

Grounded End Clamp Grounded Mid Clamp Ground Path Grounding Lug

11. Final Check

• Check and verify that all components are properly fastened and installed properly in their correct positions and locations.
• Verify and re-adjust all components as needed within the structure.

12. Hide Footing (Optional)

• Cladding of 4 bases is an option with engineer approval.

Tel : 1-800-948-5390
Email : info@chikousa.com
www.chikousa.com
9 101 East Baseline Road Buckeye, AZ 85326

THREE CAR CARPORT

Layout : 4×9 BOM

Module Dimensions : 67.9 x 44.6
Tilt Angle : 5°
Front Clearance : 111
Wind Speed
Snow Load| Modify by| Doc No.| Data| Des| J. Burton| 231130|
---|---|---|---|---|---|---|---
| | | Drw| |
Check| | | Beam & Column Set
Craft| | 4×9-5°
App| | View :| Rate| | Page /

CHIKO CARPORT- – BASE PLATE DRAWING – IN INCHES
BASEPLATEBOTTOM DIMENSION SQUARE :11 13/16″ X 11 13/16″

CHIKO CARPORT- – BASE PLATE DRAWING – IN MM
BASEPLATE BOTTOM DIMENSION SQUARE: 300MM X 300MM

CHIKO USA PREMIER CARPORT-SIDE VIEW

Mark| Modifivation| Modify by| Doc No.| Data| Des| J. Burton| 231130|
---|---|---|---|---|---|---|---|---
| | | | | Drw| |
| | | | | Check| | | |
| | | | | Craft| | | 4×6-5°
| | | | | App| | | View :| Rate| | Page /

SIDE PROFILE AND PARTS DIAGRAMS

Module Dimensions : 67.9 x 44.6
Tilt Angle : 5°
Front Clearance : 111
Wind Speed
Snow Load| Modify by| Doc No.| Data| Des| J. Burton| 231130|
---|---|---|---|---|---|---|---
| | | Drw| |
Check| | | Beam & Column Set
Craft| | 4×9-5°
App| | View :| Rate| | Page /

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