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ASSEMBLY INSTRUCTIONS RESIDENTIAL SOLUTION
CROSSRAIL GROUND MOUNT SYSTEM
USA
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3
4
6
8
14
TABLE OF CONTENTS
SAFETY REGULATIONS
MATERIALS REQUIRED
ASSEMBLY
ENGINEERING DRAWINGS
TERMS AND CONDITIONS
TABLE OF CONTENTS
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.
2 | 14 Table of Contents
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 Pagehttp://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.
3 | 14Safety Regulations
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
Material: aluminumFinish: mill, dark anodizedStandard length: 164“, custom
Bonding End Clamp Set
Material: stainless steelFinish: silver, dark
Bonding Mid Clamp Set
Material: stainless steelFinish: silver, dark
Module End Clamp Set
Material: aluminumFinish: mill, dark anodizedHardware: stainless steel
Module Mid Clamp Set
Material: aluminumFinish: mill, dark anodizedHardware: stainless steel
M10 Serrated Flange Nut and
T-Bolt 28/15 M10
Material: stainless steel
Hollaender No. 70 External CouplingMaterial: 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
Hollaender 5 EXT Extended Barrel Tee OR
Hollaender 5 EXMaterial: aluminum
Everest Pipe L Bracket Kit
Material: stainless steel, galvanized steel
4 | 14Materials Required
Optional: End Cap for CrossRail 80
Material: glass fiber reinforced polyamide
Optional: External Omega Cable
Clip
Material: polyamide, black
TORQUE SPECIFICATIONS¬ M10 T-Bolts: 25.8 lb-ft (35 Nm)
¬ M8 T-Bolts: 10 lb-ft (13.5 Nm)
¬ M8 Allen Bolts: 10.3 lb-ft (14 Nm)
TOOLS REQUIRED¬ Torque wrench (0 – 50 lb-ft)
¬ Cordless Drill (non-impact)
¬ 13mm Deep Socket
¬ 15mm Deep Socket
¬ Measuring Tape
¬ Excavation Equipment
¬ 3/8“ Hex Head Wrench
¬ Hollaender Set Screw
¬ SW6 Hex Drive
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 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.
5 | 14Materials and Tools Required
LOCATE FOOTINGS
CUT GALVANIZED PIPE
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.
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.
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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.
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.
ASSEMBLE MAIN PIPE STRUCTURE IN PLACE: HORIZONTAL PIPE
ASSEMBLE MAIN PIPE STRUCTURE IN PLACE: VERTICAL PIPE
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ASSEMBLE MAIN PIPE STRUCTURE IN PLACE: BRACINGAttach all side bracing tubing into place. Do not torque to specified rating yet.
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6 | 14Installation of CrossRail Ground Mount System
ASSEMBLY: STEP BY STEP
7 | 14Installation of CrossRail Ground Mount System
PLACE L-BRACKET ASSEMBLYAttach 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).
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ATTACH RAIL TO BRACKET
Set CrossRail 80 on to horizontal galvanized pipe at spacing required to support PV modules per the panels’ manufacturer guidelines.
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POUR CONCRETE IN PLACE
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.
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FINAL ASSEMBLY AND MISCELLANEOUS COMPONENTS
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.
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INSTALL SOLAR PV MODULESInstall solar PV modules per the steps outlined in the CrossRail Assembly Instructions (separate document):http://www.everest-solarsystems.com/us/downloads/technical-information.html
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G Wind Speed* Snow* Tie-Brace A A1
TILT
ANGLE
ASCE 7-05 /
7-10 (mph)
Ground Snow
LoadRequired? Pipe Size
Pipe
SpecifcationPost Spacing
Post Spacing
w/ V-BraceFront Back Front Back
Yes Sch. 40 7'-9" 11'-9" 2'-0" 4'-0" 2'-4" 5'-0"
Yes Sch. 80 8'-9" 13'-6" 2'-0" 4'-0" 2'-4" 5'-0"
Yes Sch. 40 9'-9" 15'-0" 2'-0" 4'-0" 2'-3" 5'-0"
Yes Sch. 80 10'-9" 16'-0" 2'-0" 4'-3" 2'-9" 5'-3"
Yes Sch. 40 5'-6" 9'-0" 2'-0" 4'-4" 3'-0" 6'-0"
Yes Sch. 80 6'-3" 10'-9" 3'-0" 5'-0" 3'-0" 6'-0"
Yes Sch. 40 7'-6" 12'-0" 2'-3" 5'-4" 3'-3" 7'-0"
Yes Sch. 80 9'-0" 13'-6" 2'-6" 6'-0" 3'-9" 7'-0"
Yes Sch. 40 5'-3" 9'-0" 2'-3" 5'-0" 3'-3" 6'-0"
Yes Sch. 80 5'-9" 9'-9" 2'-3" 5'-0" 3'-3" 6'-0"
Yes Sch. 40 7'-0" 11'-0" 2'-3" 5'-0" 3'-4" 6'-4"
Yes Sch. 80 8'-0" 10'-6" 2'-4" 5'-3" 3'-9" 7'-0"
Yes Sch. 40 5'-6" 8'-3" 3'-0" 6'-0" 3'-6" 7'-3"
Yes Sch. 80 5'-9" 8'-3" 3'-0" 6'-0" 3'-6" 7'-3"
Yes Sch. 40 7'-0" 9'-0" 3'-0" 6'-6" 3'-4" 7'-6"
Yes Sch. 80 8'-0" 10'-6" 3'-0" 7'-0" 3'-6" 8'-0"
Yes Sch. 40 4'-6" 6'-3" 3'-0" 6'-0" 3'-3" 6'-6"
Yes Sch. 80 5'-6" 7'-3" 3'-0" 6'-0" 3'-3" 7'-0"
Yes Sch. 40 6'-0" 8'-9" 3'-0" 6'-0" 3'-4" 7'-4"
Yes Sch. 80 7'-0" 11'-0" 3'-0" 6'-6" 4'-8" 8'-3"
1.5"
2"
30˚-35˚ 105 / 130 50 psf
30˚-35˚ 105 / 130 30 psf
1.5"
2"
INSTALLATION DIMENSIONS
20˚ 85 / 100 0 psf
Pipe Data
2"
1.5"
CONCRETE DEPTH (A)
30 psf90 / 10530˚-35˚
30˚-35˚ 90 / 105 50 psf
CONCRETE DEPTH (A1)
1.5"
2"
1.5"
2"
CrossRail Ground Mount Assembly Instructions US5 - 0416Product images are for illustrative purposes only. Specifi cations aresubject to change without notice. All sales of our products shall besubject to Everest Solar Systems terms and conditions, includingthe exclusive limited warranty set forth therein.
K2 Systems International: World headquarters K2 Systems GmbH, GermanyK2 Systems SARL, FranceK2 Systems SRL, ItalyK2 Solar Mounting Solutions Ltd., UK
Everest Solar Systems, LLC3809 Ocean Ranch Blvd.Suite 111Oceanside, CA 92056Tel. +1.760.301.5300info@everest-solarsystems.comwww.everest-solarsystems.com
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
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
Ready!
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