ENGR 464-02

Fall 2016

Solar Panel Support

TS Full SJ TS410 Thin-Film PV Panel
Version 1.0

Team Swirly Solar Products

Mason Nekoui, Mark Nisnisan, Timothy Tuong, Calvin Yee

TABLE OF CONTENTS

I.
II.
III.
IV.
V.
VI.

Problem Definition .
3
Design Specification
3
Assumptions.
4
Design.
4
Bill of Materials
7
Analysis..
8

I.

Problem Definition

Solar plants that are built in dry, arid environments suffer from strong winds that produce heavy loading
on solar panels and their supports. To account for wind loading with large solar panels, a support design is
to be drafted to rectify the issue. We will model around the TSolar Full SJ TS410 thin- film PV module
for the design. At 271 lbs, The TS410 module is required to be at an angle of 30 deg from the ground. In
addition, the clearance (between the TS410 module and the ground) is to be 3 ft and resist wind loading of
20 psf. Further design constraints can be found below.

II.

Design Specifications

FOS (Factor of Safety)

2.0

Clearance (feet)

Angle (deg)

30

Wind Loading (pound per square foot)

20 psf (Normal)

Panel Area (LxW)

(102.36 x 90.55)in= 61.35 ft2

(2600 x 2300)mm = 5.7 m2

Panel Thickness

0.4133858 +/- 0.019685 [10.5 +/- 0.5 mm]

Panel Weight

271 lb [123 kg]

Vertical Support

A-500 ERW Structural Steel Pipe

6" SCH 40 (6.625 OD X .280 wall)

Connection Type(s):

Bolted

Figure 1: Panel dimensions with rails

III.

Assumptions
Ground is flat
Foundation mounting is rigid
Wind pressure is perpendicular to the panel

IV. Design
Components
1. Vertical Support Beam- 6 diameter steel structural pipe; load bearing

Figure 2: Support beam (Pipe)

2. Strongback- Back support for the panel to the vertical support beam connections
Note: The strongback is cut to size out of ID 3 steel; based off drawing

Figure 3: Strongback with superstuts attatched (TOP VIEW)

3. Superstrut- Connectors between the panel and the strongback

Figure 4: Superstrut

4. Support Beam Brace Assembly- Mounting bracket that attaches tilt plates to beam
5. Tilt Plate(s)- Angled mounting brackets that attach
Installation
Step 1: Superstrut Connection
a) In order to attach the panel to the support beam it must first be connected to the
strongback.
b) First install the 4 super struts ID 1 to the front of the strongback ID 3 using
5/16 hardware (bolt, flat washer, locking washer, flat washer, nut).
Note(s): Closed, flat surface of strut, mates against strongback. Outer struts have
2 connections per corner; inner struts mounted with 4 connections spaced evenly

Figure 5: Strongback front surface with superstruts attached

Step 2: Strongback Mating

a) Lay the panel onto a flat, soft, surface with top face down.
b) With the superstruts attached, the strongback is now one assembly.
c) Attach the assembly to the panels back using 5/16 hardware bolted against the
flat side of struts
Note(s): Each strut mounted at 2 connection points. Inner struts must line up with
drilled holes in strongback

Step 3: Attach Beam Brace Assembly

a) Loosely install the hardware (bolt, flat washer, lockwasher, and hex nut) into
the 2 brace halves around support beam as shown in Figure 6 making sure the lips of the
braces sit on top of the support beam

Figure 6: Support beam mounting brace

b) Tighten bolts evenly, making sure each bolt is tightened the same amount so the
distance between braces is even on each side of the pole.
Note: Torque spec 260 in-lbs
Step 4: Tilt Plate Attachment
a) Place tilt plates against brace assembly as shown in Figure 7 using hardware
tighten down plates to braces.

Figure 7: Support beam mounting brace

b) Adjust plates to 30 degree position and torque down to hold position

Step 5: Strongback/Panel to Tilt Plate Attachment

a) To complete the setup, using at least two persons, carefully lift the panel assembly
onto the tilt plates and bolt panel at all 8 mounting locations using remaining 5/16
hardware.

Figure 8: Final panel support mounted at 30 degree angle to horizon