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Mounting systems for solar technology
ASSEMBLY INSTRUCTIONS
CrossRail Tilt Up System
www.everest-solarsystems.com
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Summary of Contents for K2 Systems Everest CrossRail 44-X
- Page 1 Mounting systems for solar technology ASSEMBLY INSTRUCTIONS CrossRail Tilt Up System www.everest-solarsystems.com...
- Page 2 Table of Contents About Us Safety Regulations Tools Overview Materials Required Bonding and Grounding Compatible Modules Dimensions Assembly Notes QUALITY TESTED – SEVERAL CERTIFICATIONS Everest Solar Systems stands for secure connections, highest quality and precision. Our customers and business partners have known that for a long time.
- Page 3 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 10 GW installed.
- Page 4 General safety information Please note that our general mounting instructions must be followed at all times and can be viewed online at www.everest-solarsystems.com/technical-information T The equipment may only be installed and operated by qualified and adequately trained installers. T Prior to installation, ensure that the product complies with on-site static loading requirements. For roof-mounted systems, the roof load-bearing capacity must always be checked.
- Page 5 Tools overview 13 mm deep socket ≥ 6,0 m 10-50 ft-lb (6 - 35 Nm) 7/16" socket ≥ 10 ft 6 mm/HW6 Allen Drive (M8 bolt) Torque overview M10 T-Bolts: 25.8 ft-lb (35 Nm) WEEB Lug 10.3: 15 ft-lb (20.3 Nm) M8 T-Bolts: 10 ft-lb (13.5 Nm) End Clamp: M8 Allen Bolts 12 ft-lb (16.3 Nm) Tools and materials for the installation of third party items such as roof attachment products, roof covering and sealing products or items used for bonding and grounding are not listed here.
- Page 6 Required Materials In order to assemble the Everest Solar Systems CrossRail system, the following listed system components are essen- tial. The piece quantities are calculated on the basis of the respective requirements. The listed item numbers facilitate the comparison of items. UL 2703 LISTED COMPONENTS All components evaluated under UL 2703 and encompassed within Everest Solar System’s UL 2703 Listing shown be- low.
- Page 7 Tilt Connector Set | 4000505 Material: aluminum Finish: mill Hardware: stainless steel Everest Ground Lug, 13mm Hex | 4000006-H Material: aluminum Hardware: stainless steel Finish: tin-plated Burndy WEEB Lug 10.3 + Hardware | 4000622 WEEB Lug Material: tin plated copper Hardware: stainless steel Optional: Micro Inverter and Optimizer Moun- | 4000629-H...
- Page 8 Required Materials NON UL LISTED COMPONENTS Yeti Clamp (Hidden End Clamp), 13mm Hex | 4000050-H 30-50 mm Material:aluminum Hardware: stainless steel Finish: mill Aluminum End Clamp Set | multiple Material: stainless steel Finish: silver, black Hardware: stainless steel EverFlash XP Comp Kit | 4000060 4000061 Material: galvalume...
- Page 9 Bonding and Grounding Appropriate means of bonding and grounding are required by regulation. The information provided in this manual shall always be verified with local and national building codes. Everest Solar Systems has obtained a UL 2703 system listing from Underwriter’s Laboratories (UL). A sample bonding path diagram is shown in Figure 1 below.
- Page 10 Compatible Modules Everest's CrossRail Tilt Up system was tested with the following: T UL/NRTL Listed Axitec Modules: T UL/NRTL Listed Hanwha Q Cells Modules: T CONTINUED - Hanwha Q Cells Modules: · AC-xxP/156-60S · Q.PEAK- G4.1/MAx xxx · Q.Plus BFR-G4.1xxx ·...
- Page 11 T CONTINUED - LG Electronics Inc. Modules: T CONTINUED - Longi Modules: T UL/NRTL Listed Panasonic Modules: · LGxxxN2W-A5 · LR6-72-xxxM · VBHNxxxSA16 · LGxxxS2W-A5 · LR6-72BK-xxxM · VBHNxxxKA01 · LGxxxN2T-A5 · LR6-72HV-xxxM · VBHNxxxKA03 · LGxxxQ1C-A5 · LR6-72PE-xxxM · VBHNxxxKA04 ·...
- Page 12 Compatible Modules continued Everest's CrossRail Tilt Up system was tested with the following: T UL/NRTL Listed Silfab Modules: T CONTINUED - Trina Solar Modules: · SLAxxxM · TSM-DD06H.05(II) · SLG-M-xxx · TSM-DD06M.t5(II) · SLA-x-xxx · TSM-DD06H.T5(II) · SLG-x-xxx · TSM-PE15H ·...
- Page 13 CrossRail Tilt Up Install Dimensions The CrossRail Tilt Up System is a fully customizable solution. Figure 2 and Table 1 below provide recommended installation dimensions based upon a standard 60-cell and 72-cell PV module with 1/6 - point clamping locations. Always ensure that the dimensions are suitable for the project site. Desired Tilt Angle Dimension Description...
- Page 14 Assembly CUT RAILS TO LENGTH Using Table 1 as a guide, cut the CrossRail 44-X/48-X/48-XL profiles to the appropriate lengths according to the desired tilt angle. Materials required: CrossRail 44-X or 48-X or 48-XL, cutting tool (i.e. Sawzall, etc.). INSTALL ROOF ATTACHMENT Select and install the appropriate roof attachment according to the manufacturer’s instructions and the structural calculations for CrossRail Tilt Up System.
- Page 15 OPTIONAL: INSTALL EVERFLASH AND L-FOOT Line up pilot hole with the EverFlash flashing hole. Insert the lag bolt through the EPDM bonded washer, the L-foot, the gasketed hole in the flashing and into the rafter. Torque: The range is between 8.3 - 11.6 ft-lb depending on the type of wood and time of year.
- Page 16 ATTACH BRACKET TO REAR TILT LEG Attach the rear Tilt Leg to the Tilt Connector using two M10 T-bolts and two Serrated Hex Nuts. Make sure the connector is flush along bottom of the rail. Torque: 25.8 ft-lbs (35Nm). Note: If installing a 7 degree landscape configuration, do not tighten the bottom hex nut on the connector.
- Page 17 OPTIONAL: 7 DEGREE TILT IN LANDSCAPE ONLY Position the leg set assembled in Steps 4 and 5 above so that it is flush against the vertical wall of the L-Foot or T-Foot X. Hand tighten the bottom of the Tilt Connector to the Foot with the M10 T-bolt and Serrated Hex Nut from the Tilt Connector Set.
- Page 18 ALIGN RAILS Align the two rail ends next to each other. SLIDE RAIL CONNECTOR Slide the rail connector from below the rails, centering the connector between the two rail ends. Ensure the rail connector does not interfere with an L-Foot or T-Foot or roof attachment. CONNECT RAILS Attach the rail connector using two M10 T-bolts (use bon- ding T-bolts with dark rail) and Serrated Hex Nuts per side (if...
- Page 19 OPTIONAL: ATTACH MICRO INVERTERS Using the Micro Inverter and Optimizer Mounting Kit Hardware from Everest Solar Systems, attach your chosen device to the top channel of CrossRail. Torque: 10.3 ft-lb (14 Nm). Materials required: Micro Inverter Mounting Kit includes: M8 x 13 mm Hex Bolt, M8 lock washer, M8 flat washer, MK3 ATTACH END CLAMPS Insert the MK3 slot nut of the pre-assembled end clamps into the...
- Page 20 ATTACH MID CLAMPS Insert the MK3 slot nut of the pre-assembled mid clamps into the top channel on CrossRail. While slightly lifting the plastic tabs, rotate 90 degrees clockwise to engage the MK3 into the channel. Attach the mid clamps to the module at the specified locations per the PV module manufacturer’s installation instructions.
- Page 21 SYSTEM GROUNDING IMPORTANT NOTE CrossRail components are required to be electrically bonded and grounded via the Everest Ground Lug or Burndy’s WEEB Lug 10 and the use of #6 or #8 AWG solid copper wire. A minimum of one lug is required per each inde-pendent row of modules.
- Page 22 Notes...
- Page 23 Notes...
- Page 24 Mounting systems for solar technology THANK YOU FOR CHOOSING AN EVEREST MOUNTING SYSTEM. Systems from Everest Solar Systems are quick and easy to install. We hope these instructions have helped. Please contact us with any ques- tions or suggestions for improvement. Our contact information: www.everest-solarsystems.com/contact Service Hotline: +1.760.301.5300...
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