3 - Everest Solar Systems

ASSEMBLY INSTRUCTIONS
RESIDENTIAL SOLUTION
CROSSRAIL GROUND MOUNT SYSTEM
USA
TABLE OF CONTENTS
TABLE OF CONTENTS
2
SAFETY REGULATIONS
3
MATERIALS REQUIRED
4
ASSEMBLY
6
ENGINEERING DRAWINGS
8
TERMS AND CONDITIONS
14
ENGINEERING STRENGTH IS AT OUR CORE
With sophisticated product innovations and a deep customer focus, Everest Solar is the engineering leader for all your mounting
system needs. We are the US division of K2 Systems, one of Europe’s market leaders with more than 3.0 GW installed.
We offer proven product solutions and innovative designs. Wind tunnel testing along with advanced structural and electrical
validation to facilitate permitting, design and installation. Our designs result in cost competitive racking systems with dedicated
support that will position you to win more projects.
We partner with our customers and suppliers for the long-term. High quality materials and cutting edge designs provide a
durable, yet functional system. Our product line is comprised of a few, coordinated components that lower the cost of materials,
and simplify installation, saving you time and money. All backed by German engineering, a long track record of quality and a
company that is here to stay.
Thank you for choosing Everest Solar Systems for your Solar PV Project.
Table of Contents
2 | 14
GENERAL SAFETY INSTRUCTIONS
Everest Solar Systems’ General Assembly Instructions must be followed to maintain the exclusive, limited product warranty.
You can access these instructions at Everest Technical Info Page
http://www.everest-solarsystems.com/us/downloads/technical-information.html or by contacting us directly.
In general, the following applies:
¬ Systems should be installed by experienced contractors licensed and qualified to perform the work with professional
workmanship and quality.
¬ Before installation, Contractor must verify that the system meets all applicable laws, regulations, ordinances, and codes.
Contractor shall verify that the roof or other structures to which the system is being attached are capable of carrying the system
loads. For information about the dead loads of the various system components, Contractor should review the Everest Technical
information page at http://www.everest-solarsystems.com/us/downloads/technical-information.html or contact us
directly.
¬ Contractor is solely responsible for work safety and accident prevention regulations and corresponding standards and
regulations of the applicable occupational safety and health agency are followed, including:
- Safety clothing is worn such as safety helmets, work shoes, and gloves.
- Where required, the contractor should use fall protection, scaffolding with arrestor equipment and other approved methods
for worker safety.
¬ Contractor shall verify that it is using the most current instructions by downloading the latest version from our website or
contacting our office directly.
¬ Module manufacturer installation guides must be followed. Please use approved electrical bonding and grounding components
that are required by the local or national codes and AHJ.
¬ A copy of these instructions must be on site, and read and understood by all workers during installation.
¬ In the event our general installation and assembly instructions are not followed, or that not all system components and
assemblies are used according to these instructions, or that components are used which were not obtained from us, Everest
Solar Systems is not liable for any resulting defects and damages, and the exclusive, limited warranty will be void.
¬ The exclusive, limited product warranty shall apply only if all instructions are strictly adhered to and the system is correctly
installed. Everest Solar Systems disclaims any and all warranties, express or implied, including without limitation any warranties
of merchantability and fitness for a particular purpose other than as set forth in the exclusive, limited warranty in the terms and
conditions of sale, which can be viewed under on our website:
http://www.everest-solarsystems.com/us/downloads/technical-information.html
¬ The dismantling of the system should be in reverse order of these assembly instructions.
Safety Regulations
3 | 14
CrossRail for Ground Mount:
¬ Pre-engineered System:
- 4 rows in landscape
- 20-35° tilt
- 0-50 lbs Snow, 100-130 mph Wind
- Low part count
¬ Uses the Everest CrossRail 80 & L-Bracket kit on
standard 1.5 - 2.0“ pipe & Hollaender connectors
¬ Low cost system with easy installation
CrossRail 80
M10 Serrated Flange Nut and
Material: aluminum
Finish: mill, dark anodized
Standard length: 164“, custom
T-Bolt 28/15 M10
Bonding End Clamp Set
Hollaender No. 70 External Coupling
Material: stainless steel
Finish: silver, dark
Material: aluminum
Bonding Mid Clamp Set
Hollaender 5 EXT Extended Barrel
Tee
Material: stainless steel
Finish: silver, dark
Module End Clamp Set
Material: aluminum
Finish: mill, dark anodized
Hardware: stainless steel
Module Mid Clamp Set
Material: aluminum
Finish: mill, dark anodized
Hardware: stainless steel
Everest Pipe L Bracket Kit
Material: stainless steel, galvanized steel
Material: stainless steel
OR
Hollaender 5 EX
Material: aluminum
Hollaender 17E Adj. Elbow
OR
Tee-E Assembly + Hollaender 17
Adjustable Elbow or Tee Assembly
OR
Hollaender 17x-9 Adjustable Elbow
or Tee Assembly
Material: aluminum
Materials Required
4 | 14
Optional: External Omega Cable
Optional: End Cap for CrossRail 80
Clip
Material: glass fiber reinforced polyamide
Material: polyamide, black
Optional: HEYClip SunRunner Cable
Clip SS, S6404
Material: stainless steel
TOOLS AND TORQUE SPECIFICATIONS REQUIRED
Everest Solar Systems are designed to make installation easy and fast. The basic tools required to assemble the parts are listed below as a guide.
TOOLS REQUIRED
TORQUE SPECIFICATIONS
¬ Torque wrench (0 – 50 lb-ft)
¬ M10 T-Bolts: 25.8 lb-ft (35 Nm)
¬ Cordless Drill (non-impact)
¬ M8 T-Bolts: 10 lb-ft (13.5 Nm)
¬ 13mm Deep Socket
¬ M8 Allen Bolts: 10.3 lb-ft (14 Nm)
¬ 15mm Deep Socket
¬ Measuring Tape
¬ Excavation Equipment
¬ 3/8“ Hex Head Wrench
¬ Hollaender Set Screw
¬ SW6 Hex Drive
Tools and materials for the installation of third party items or items used for bonding and grounding are not listed here. Please refer to the
instructions of those third party products.
Materials and Tools Required
5 | 14
ASSEMBLY: STEP BY STEP
1
of 10
LOCATE FOOTINGS
Locate and excavate footings per spacing requirements shown on layout plan (sheet
S100), layout elevation (sheet S101), and installation schedule (sheet S102).
Materials required: Tape measure, string line, drill.
2
CUT GALVANIZED PIPE
of 10
Cut galvanized pipe, including vertical posts and horizontal beams, to required lengths.
Drill holes and place rebar in pipe as shown on elevation (sheet S101).
¬ Slide Hollaender aluminum tees (#5EXT-8, #5EX-8, #5EX-9), elbows (#17E, #17),
and couplers (#70) if required on to horizontal pipe lengths.
3
of
of 10
8
ASSEMBLE MAIN PIPE STRUCTURE IN PLACE:
HORIZONTAL PIPE
Use stakes or an alternative temporary shoring method to place horizontal galvanized
pipe at the elevations required to achieve specified tilt (see sheet S101, sheet S102).
¬ Slide Hollaender aluminum tees (#5EXT-8, #5EX-8, #5EX-9) and elbows
(#17E, #17) and tighten set screw enough to prevent fittings from sliding.
3
4
of 10
8
of
ASSEMBLE MAIN PIPE STRUCTURE IN PLACE:
VERTICAL PIPE
Connect vertical posts to horizontal pipe using appropriate tee fitting and use
Hollaender tool or hex drive to tighten bottom set screw to required torque value
(sheet S103).
At this point, the vertical post pipe should still be able to rotate freely around the
horizontal pipe.
5
of 10
ASSEMBLE MAIN PIPE STRUCTURE IN PLACE:
BRACING
Attach all side bracing tubing into place. Do not torque to specified rating yet.
Installation of CrossRail Ground Mount System
6 | 14
6
PLACE L-BRACKET ASSEMBLY
of 10
Attach U-Bolt to L-Bracket around horizontal pipe using hex nuts as shown on detail B
(sheet S104).
Attach L-Bracket to CrossRail 80 using M10 T-Bolts and M10 Serrated Flange Nut
(sheet S104).
7
of 10
ATTACH RAIL TO BRACKET
Set CrossRail 80 on to horizontal galvanized pipe at spacing required to support PV
modules per the panels’ manufacturer guidelines.
8
POUR CONCRETE IN PLACE
of 12
Ensure vertical pipe posts are plumb and located in foundation excavations per the
spacing requirements shown in the layout plan, layout elevation, and installation
schedule (sheets S100, S101, and S102).
Pour or pump mixed concrete into excavated footings and allow time for curing.
9
FINAL ASSEMBLY AND MISCELLANEOUS COMPONENTS
of 10
Remove temporary shoring and, if required, install piping for Tie-Brace (sheets S100,
S101 and S103) and V-Brace (sheets S100, S101 and S105) as outlined in the
installation schedule (sheet S102).
Tighten all set-screws as shown on the detail sheets (sheets S103, S104). Adjust
CrossRail 80 to final location as required to support PV modules.
Tighten U-Bolt hex nuts to torque requirements shown on sheet S104. Ensure M10x
lock nuts are tightened to specified torque.
10
of 10
INSTALL SOLAR PV MODULES
Install solar PV modules per the steps outlined in the CrossRail Assembly Instructions
(separate document):
http://www.everest-solarsystems.com/us/downloads/technical-information.html
Installation of CrossRail Ground Mount System
7 | 14
G
Wind Speed*
Snow*
Tie-Brace
TILT
ANGLE
ASCE 7-05 /
7-10 (mph)
Ground Snow
Load
Required?
20˚
30˚-35˚
30˚-35˚
30˚-35˚
30˚-35˚
85 / 100
90 / 105
90 / 105
105 / 130
105 / 130
0 psf
30 psf
50 psf
30 psf
50 psf
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
INSTALLATION DIMENSIONS
Pipe Data
A
A1
Pipe Size
1.5"
2"
1.5"
2"
1.5"
2"
1.5"
2"
1.5"
2"
CONCRETE DEPTH (A)
CONCRETE DEPTH (A1)
Pipe
Specifcation
Post Spacing
Post Spacing
w/ V-Brace
Front
Back
Front
Back
Sch. 40
Sch. 80
Sch. 40
Sch. 80
Sch. 40
Sch. 80
Sch. 40
Sch. 80
Sch. 40
Sch. 80
Sch. 40
Sch. 80
Sch. 40
Sch. 80
Sch. 40
Sch. 80
Sch. 40
Sch. 80
Sch. 40
Sch. 80
7'-9"
8'-9"
9'-9"
10'-9"
5'-6"
6'-3"
7'-6"
9'-0"
5'-3"
5'-9"
7'-0"
8'-0"
5'-6"
5'-9"
7'-0"
8'-0"
4'-6"
5'-6"
6'-0"
7'-0"
11'-9"
13'-6"
15'-0"
16'-0"
9'-0"
10'-9"
12'-0"
13'-6"
9'-0"
9'-9"
11'-0"
10'-6"
8'-3"
8'-3"
9'-0"
10'-6"
6'-3"
7'-3"
8'-9"
11'-0"
2'-0"
2'-0"
2'-0"
2'-0"
2'-0"
3'-0"
2'-3"
2'-6"
2'-3"
2'-3"
2'-3"
2'-4"
3'-0"
3'-0"
3'-0"
3'-0"
3'-0"
3'-0"
3'-0"
3'-0"
4'-0"
4'-0"
4'-0"
4'-3"
4'-4"
5'-0"
5'-4"
6'-0"
5'-0"
5'-0"
5'-0"
5'-3"
6'-0"
6'-0"
6'-6"
7'-0"
6'-0"
6'-0"
6'-0"
6'-6"
2'-4"
2'-4"
2'-3"
2'-9"
3'-0"
3'-0"
3'-3"
3'-9"
3'-3"
3'-3"
3'-4"
3'-9"
3'-6"
3'-6"
3'-4"
3'-6"
3'-3"
3'-3"
3'-4"
4'-8"
5'-0"
5'-0"
5'-0"
5'-3"
6'-0"
6'-0"
7'-0"
7'-0"
6'-0"
6'-0"
6'-4"
7'-0"
7'-3"
7'-3"
7'-6"
8'-0"
6'-6"
7'-0"
7'-4"
8'-3"
Ready!
THANK YOU FOR CHOOSING AN EVEREST SOLAR SYSTEMS
MOUNTING SYSTEM.
Systems from Everest Solar Systems are fast and simple to install. Please contact us if you have any questions or
suggestions for improvements. We are looking forward to receive your call on our
Service-Hotline +1 760.301.5300
TERMS AND CONDITIONS
Product images are for illustrative purposes only. Specifications are subject to change without notice. All sales of our products shall be subject to
Everest Solar Systems terms and conditions, including the exclusive limited warranty set forth therein. The terms and conditions can be found at
http://www.everest-solarsystems.com/us/downloads/technical-information.html
Everest Solar Systems, LLC
3809 Ocean Ranch Blvd.
Suite 111
Oceanside, CA 92056
Tel. +1.760.301.5300
[email protected]
www.everest-solarsystems.com
K2 Systems International:
World headquarters
K2 Systems GmbH, Germany
K2 Systems SARL, France
K2 Systems SRL, Italy
K2 Solar Mounting Solutions Ltd., UK
CrossRail Ground Mount Assembly Instructions US5 - 0416
Product images are for illustrative purposes only. Specifications are
subject to change without notice. All sales of our products shall be
subject to Everest Solar Systems terms and conditions, including
the exclusive limited warranty set forth therein.