1-Car Premier Steel Solar Carport

Product Information

Specifications

• Model: CK- Steel Solar Carport Gazebo
• Version: 03.25.2024VO2
• Language: English
• Main Components:
  • Base Plate
  • Front Column
  • Rear Column
  • Support Beam
  • Lower Horizontal Beam
  • Diagonal Brace
  • L-Angle Support
  • C Rail Fix Kit
  • C-Channel
  • M-Rail
  • Top Column Adapter
• Installation Tools Required:
  • Wrench
  • Gloves
  • Chalk Line
  • Tape Measure
  • Rubber Mallet
  • Hardhat
  • Safety Glasses

Product Usage Instructions

Maintenance

1. When signs of rust appear or paint is peeled, remove rust and
   repaint affected areas.

2. Check bolts annually and after major weather events, tighten
   according to torque specs.

3. If columns are hit, replace them immediately.

Warnings

If any structural component is damaged, such as column, beam,
base plate, or rail, they must be replaced immediately.

Measurement Note

All measurements are converted from mm to inches with slight
variations. Review construction drawings for accurate base plate
placement.

Installation Steps

1. Refer to the most recent installation manual.
2. Ensure all components are present.
3. Use the required tools listed in the manual.
4. Follow the step-by-step instructions for assembly.
5. Check all connections for security.
6. Contact CHIKOUSA for any questions or concerns.

FAQ

Q: What should I do if I notice signs of rust on the

structure?

A: Remove the rust and repaint the affected areas as soon as
possible to prevent further damage.

Q: How often should I check the bolts?

A: Bolts should be checked annually and after any major weather
occurrences, tightening them according to torque
specifications.

Q: What should I do if a structural component is damaged?

A: Any damaged structural component, including columns, beams,
base plates, or rails, must be replaced immediately to maintain the
integrity of the system.

Q: Why is it important to call 811 before digging?

A: Calling 811 or visiting their website is crucial to ensure
you don’t unintentionally dig into underground utility lines while
installing footings for the structure.

CK- | STEEL SOLAR CARPORT | GAZEBO
1-CAR PREMIER STEEL SOLAR CARPORT | GAZEBO
INSTALLATION MANUAL
VERSION: 03.25.2024VO2 | ENG

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.

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REQUIRED INSTALLATION TOOLS

WRENCH

GLOVES

CHALK LINE

TAPE MEASURE

RUBBER MALLET

HARDHAT

SAFETY GLASSES

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MAIN COMPONENTS

1421 8 M RAIL

C-RAIL FIXED KIT

BASE PLATE

16 1 2 LOWER BEAM & DIAGONAL BRACE ADAPTER

10 3 16 TOP COLUMN ADAPTER

10 3 16 DIAGONAL BRACE ADAPTER

MID-CLAMP

END-CLAMP

WATER CHANNEL

WATER-PROOF RUBBER

16 1 2
LOW BEAM/DIAGONAL BRACE ADAPTER

111 FRONT COLUMN

1261 2 REAR COLUMN

224 7 16 L-ANGLE SUPPORT

228 5 16 SUPPORT BEAM

1681 8 LOWER HORIZONTAL BEAM

47 1 4 DIAGONAL BRACE

149 5 8 C-CHANNEL

NOTE Customer needs to source materials for footings based on structural engineer specifications.

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MAIN COMPONENTS

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

11 4

7

10

21
12 19

9

5

14 13

16

6

15

3

20

15

13 2

8

16

1

18 17

No Description
1 Base Plate 2 Front Column 111 3 Rear Column 126 1 2 4 Support Beam 228 3 8 5 Lower Horizontal Beam 1681 16 6 Diagonal Brace 47 1 4 7 L-Angle Support 224 7 16 8 C Rail Fix Kit 9 C-Channel 1495 8 10 M-Rail 1421 8 11 Top Column Adapter 10 3 16

QTY
4 2 2 2 2 4 1 12 6 8 4

No Description
12 Low Beam & Diagonal Brace Adapter 161 16 13 End Clamp 30, 35, & 40MM 14 End Clamp Share Plate 15 M1035 Bolt Kit 16 M16180 Bolt Kit 17 Water Channel 18 Waterproof Rubber 19 Mid Clamp 20 Mid Clamp Share Plate 21 Diagonal Brace Adapter 10 3 16

QTY
4 16 16 48 104 9
16 16 4

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FRONT VIEW

SIDE VIEW

OVERHEAD VIEW

LARGE FORMAT MODULE VIEW

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COMPONENTS LIST

CAT

Picture

1

2 3

Description Part
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
M Rail CK-ZEM-010-5760
Water Channel CK-009-1062

Details
Front Columns Rear Columns Base Plate Support Beam Top Column Adapter Lower Horizontal Beam Diagonal Brace Low Beam & Diagonal Brace Adapter HDG Bolt M1035 HDG Bolt M16180 HDG Nut M10 HDG Nut M16 HDG Washer M10 HDG Washer M16 HDG Spring Washer M10 HDG Spring Washer M16 M Water-proof Rail
Self Tapping Screw

QTY
2 2 4 2 4 2 4 4 48 104 48 104 48 104 96 208 8
30

Water Channel

9

4

Water Prooof Strip CK-IP-160-1133

Water Proof Rubber

Purlin ‘C’ Channel

5

CK-PL-C140-001-016- C-Channel 149 5 8

6

6000

6

L Angle Support

224 3 8

1

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6

CAT

Picture

7

8 9 10

Description Part
C RAIL Purlin Fix Kit CK-PL-GT001-016-14
Mid Clamp CK-782-4-60-Q
BRACKET # #CK-A845-801
End Clamp CK-737-3-60-Q
BRACKET # #CK-1845-801 Grounding Lug
CK-GTC-R2

Details
Purlin Fixed Kit HDG Bolt M1035 HDG Bolt M16140 HDG Nut M10 HDG Nut M16 HDG Washer M10 HDG Washer M16 HDG Spring Washer M10 HDG Spring Washer M16 35mm Mid Clamp 845 Share Plate M Grounding Plate Self Tapping Screw SS304 Bolt M845 SS304 Spring Washer M8 35mm End Clamp 845 Share Plate M Grounding Plate Self Tapping Screw SS304 Bolt M845 SS304 Spring Washer M8 Grounding lug – weeb lug 8.0 SS304 outer hex bolt 1/4″ 0.6″ SS304 inner hex bolt M820 SS304 inner hex bolt M8*20

QTY
12 48 24 48 24 96 48 48 24 16 16 16 64 16 16 16 16 16 24 12 12 6 6 6 6

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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.

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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.

Products Name Base

Quantity 4

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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

Products Name Top Column Adapter M16*140mm Bolt Kits (1 big flat washer + 1spring washer + 1 nut) Low Beam/Diagonal Brace Adapter C-Rail Fix Kit

Quantity 4 32 4 12

A

B1 & B2

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4. Connect Columns Attach Columns to base plate
Products Name Front Columns — 111″ Rear Columns — 126 1 2 M16*180mm Bolt Kits (1 flat washer + 1 spring washer + 1 nut)

Quantity 2 2 16

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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 Lower Horizontal Beam 168 1 16 Support Beam 228 5 16 Diagonal Brace 47 3 16

Quantity 2 2 4

3

1

2

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6. Fix C Rail
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 C Rail — 149 5 8 C-Rail Fix Kit M1040mm Bolt Kits (1 flat washer + 1 spring washer + 1 nut) M16140mm Bolt Kits (1 flat washer + 1 spring washer + 1 nut)

Quantity 6 12 48 24

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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-Mrails in parallel on a flat level surface, then lay 3 or 4 modules on top of the M-Rails, ensuring proper spacing, then mark your share plate locations. Use these location measurements to install the remaining share plate locations on the remaining M-Rails. (3 or 4 module option correlates with your overall array configuration).

Products Name
M Rails — 142 1 8 Share Plates Mid Clamps End Clamps M6.3*16

Quantity
8 32 16 16 64

L1

L2

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L3

L2

L3

L2

L4

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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 4qty M-Rails down on flat level surface; place 3 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 M Rails 142 1 8 M6.3*16

Quantity 8 36

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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

Products Name Modules Rubber Water channel

Quantity 18 or 24
1 Roll 9

1
2 3

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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 the 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
6 7 8 9 10

Diameter [inches] 0.162 0.1443 0.1285 0.1144 0.1019

Diameter [mm] 4.1148 3.66522 3.2639 2.90576 2.58826

Resistance [Ohm / 1000ft.] 0.3951 0.4982 0.6282 0.7921 0.9989

Resistance [Ohm / km] 1.295928 1.634096 2.060496 2.598088 3.276392

Max Current [Amperes]

Max Frequency for 100% skin depth

37

1100 Hz

30

1300 Hz

24

1650 Hz

19

2050 Hz

15

2600 Hz

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Grounding ­ Lug and Wiring Diagram

Grounded End Clamp

Grounded Mid Clamp

8 AWG or Greater

Ground Path

Grounding Lug

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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.

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