CHIKO USA CK-4-CAR PREMIER Residential Steel Carport Instruction Manual

CHIKO USA CK-4-CAR PREMIER Residential Steel Carport

Specifications

• Model: CK- | STEEL SOLAR CARPORT | GAZEBO
• Version: 03.19.23 VO2 | ENG

Product Information

The CK- Steel Solar Carport Gazebo is a premium carport system designed to provide shelter for up to 4 cars. It features durable steel construction with various components for a sturdy and reliable structure.

Installation Instructions

• Step 1: Preparation
  Ensure you have all the required installation tools including a wrench, gloves, chalk line, tape measure, rubber mallet, hardhat, and safety glasses.

• Step 2: Main Components Assembly
  Refer to the main components list provided in the manual and start assembling the base plate, columns, support beams, diagonal braces, and other components as per the diagram.

• Step 3: Bolting and Securing
  Check all bolts for tightness and secure all connections according to torque specifications. Ensure all components are properly aligned and securely fastened.

• Step 4: Maintenance
  Regularly inspect the structure for any signs of rust, peeling paint, or damage. Replace any damaged components immediately to maintain structural integrity.

FAQ

• What should I do if I notice signs of rust on the structure?
  When signs of rust appear, take steps to remove the rust and repaint the affected areas to prevent further corrosion.

• How often should I check the bolts on the structure?
  Check the bolts at least once a year and after any major storm or weather occurrence to ensure all connections are secure.

• What should I do if any structural component is damaged?
  If any structural component such as a column, beam, base plate, or rail is damaged, it must be replaced immediately to maintain safety and stability.

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.
   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

MAIN COMPONENTS

Overview
The following is a diagram that lists the main components of the CK- Carport System.

9

| C-Channel 2201 2| ****

6

C-Channel 2151 16
C-Channel 1209 16
10| M-Rail 1421 8| 20
11| Top Column Adapter 10 3 16| 6
---|---|---
12| Low Beam & Diagonal Brace Adapter 161 16| 6
13| End Clamp 30, 35, & 40MM| 16
14| End Clamp Share Plate| 16
15| M1035 Bolt Kit| 168
16| M16180 Bolt Kit| 156
17| Water Channel| 36
18| Waterproof Rubber|
19| Mid Clamp| 88
20| Mid Clamp Share Plate| 88
21| Diagonal Brace Adapter 103 16| 6
22| C-Channel Splice| 12

PRODUCT OVERVIEW

COMPONENTS LIST

INSTALLATION STEPS

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.

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.

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

Connect Columns
Attach Columns to base plate

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

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)

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.

Fix M Rail

• Use M6.3 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

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

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

Grounding – Lug and Wiring Diagram

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.

Hide Footing (Optional)
Cladding of 4 bases is an option with engineer approval.

WORLD LEADING MANFACTURE

FOUR CAR CARPORT

bracket)

| 160
17| M6. 3*25 (M Ra  C Ra )| 208

CHIKO CARPORT- – BASE PLATE DRAWING – IN INCHES

BASEPLATE BOTTOM DIMENSION SQUARE :11 13/16″ X 11 13/16″

BASEPLATE BOTTOM DIMENSION SQUARE: 300MM X 300MM

CHIKO USA PREMIER CARPORT-SIDE VIEW

SIDE PROFILE AND PARTS DIAGRAMS

ABOUT COMPANY

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

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