lprgm 3 assembly instructions version 1 rev a

8/12/2019 LPRGM 3 Assembly Instructions Version 1 Rev A

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Version 1, RevA

PCN 040412-1

Low-Profile Roof/Ground Mountfor 3 to 6 Modules(LPRGM)

ASSEMBLY INSTRUCTIONS

step-by-step

assembly and installation


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Assembly Instructions, LPRGM 3 to 6 Modules (Version 1, Rev A)

A Few words about these Assembly Instructions

These instructions:

Do not include any information on the selection or installation ofattaching hardware to be mounted to the roof substrate or concretefoundation. For information on compatible roof attaching hardware,see our publication titled Power Rail Design Guidelines.

Begin after all attaching hardware has been installed and secured to theroof substrate or concrete foundation.

Are intended to be used by individuals with sufficient technical skillsfor the task. Knowledge and use of hand tools, measuring devices andtorque values is also required.

Include various precautions in the forms of Notes, Cautions, and

Warnings. These are to assist in the assembly process and/or to drawattention to the fact that certain assembly steps may be dangerous andcould cause serious personal injury and/or damage to components.Following the step-by-step procedures and these precautions shouldminimize the risk of any personal injury or damage to componentswhile making the installation an efficient process.

1/2 inch wrench or socket for 5/16 inch module clamp hardware

Torque wrench

Ratchet wrench

Ratchet extension bar

Framing square

Tape Measure

For questions on a specific installation please call us or e-mail us at:

Phone: 800-260-3792

Email: [email protected]

Required Tools

Low-Profile Roof/Ground Mount for 3 to 6 Modules(LPRGM)

WARNING:Follow theprocedures andprecautions inthese instructionscarefully.

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Low-P

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Figure 3-2: Attaching Telescoping and Optional One-Piece Legs to Strongbacks

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Step 3: Attach Leg to Strongback

These instructions cover two types ofLegs: Telescoping and One-Piece.Telescoping Legs are standard while theOne-Piece Legs are sold as an option.

Both types are secured to the Strongbackusing 5/16" x 3/4" carriage bolts andflange nuts. Figure 3-2 shows theTelescoping and One-Piece Legs.

A. Make a mark on the Strongback,14" from the northern end. (SeeFigure 3-1)

B. Slide 5/16" x 3/4" carriage bolt into the Strongback, aligning bolt with the14" mark previously made on the Strongback. (See Figure 3-2)

C. Align mounting hole of Leg to carriage bolt and secure with 5/16" flange

nut. Finger tighten for now.

5/16"FlangeNut

One-PieceLeg (optional)

5/16" x 3/4"CarriageBolt

N

S

Align to Markon Strongback

5/16"FlangeNut

TelescopingLeg

5/16" x 3/4"

BoltCarriage

N

S

Align to Markon Strongback

Figure 3-1: Measure and Mark LegAttachment Point on Strongback


Mark herefor Leg

AttachmentPoint

NS

From Northern End14"

Strongback


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WARNING:This is a twoperson activitydue to the

difficultiesassociated withworking on asloped rooftop.The Strongbackand Leg assemblyis large andawkward. Oneperson shouldhold and align theStrongback whilea second personsecures the leg tothe northern L

Foot. Failure to doso could lead toserious personalinjury and/ordamagedcomponents.

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Step 4: Attach Legs to Northern L-Feet

These instructions cover two types of Legs; Telescoping and One-Piece. Both typesare secured to the L-Foot using a 5/16" x 1" hex bolt and hardware.

If using a Telescoping Leg, it may be necessary to loosen the two telescoping lock

bolts in order to extend or shorten the leg as needed to align the mounting hole ofthe leg with the slotted hole of the northern L-Foot.

A. Raise northern end of Strongback and align mounting hole of Leg to slottedhole of northern L-Foot. Secure with 5/16" x 1" bolt, flat washers, lockwasher and nut.

B. Go back and check that the Leg and the L-Foot position haven't shifted fromtheir marks on the Strongback. Adjust to align as needed.

C. Return to tighten and torque hardware as follows:

- Flange Nuts securing Strongback to L-Foot:

- Flange Nuts securing Leg to Strongback:

- Hardware securing Leg to L-Foot:- Two Telescoping Leg lock bolts:

Torque to 14-16 ft.-lbs.


Torque to 14-16 ft.-lbs.Torque to 14-16 ft.-lbs.

Figure 4-1: Attaching Leg to Northern L Foot

N

S

NorthernL-Foot

NorthernL-Foot

5/16" x 1"Bolt

5/16" x 1"Bolt

FlatWasher

FlatWasher

TelescopingLock Bolts

Strongback

See ViewsBelow

Leg(TelescopingShown)

FlatWasher

FlatWasherLock

WasherLockWasher

5/16" Nut 5/16" Nut

One-Piece Leg (optional)

48"

Telescoping Leg



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Step 5: Installing Rail-to-Rail Brackets

Power Rails attach to the Strongbacks via Rail-to Rail mounting brackets, 5/16" x3/4" turn bolts and flange nuts. The N-S span of the Rail-to-Rail brackets on theStrongback is dependent on the type/size of module being used. If the modulemanufacturer has provided specific clamping locations, use those specifications; if

none are specified by the manufacturer, use a factor of 20-percent of the modulelength to determine the N-S span of the Rail-to-Rail brackets. (See Figure 5-1below)

Once the span is determined, measure and mark the positions of the Rail-to-Railbrackets on each of the Strongbacks.

TM

Figure 5-1: Positioning the Rail-to-Rail Brackets on the Strongback

NS

Rail-to-RailBracketPosition

Rail-to-RailBracketPosition

Strongback

20%of Module

length

20%of Module

length

60%of Module

length

ModuleLength

Modul

e

(Continued)



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NOTE:Use care inaligning the Rail-to-Rail bracketsfrom oneStrongback to the

next. This willgreatly assist inthe installation ofthe Power Rails.

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NOTE:Turn Bolts must belocked into thechannel by rotatingclockwise 90-degrees. Use theindicator slot on

the threaded endto identify whetheror not a Turn Bolthas been locked.

Indicator Slotshown in Red

Locked

Turn Bolt shownin cStrongback

hannel of

Align and install the Rail-to-Rail brackets to the marks made on the Strongback.

A. Insert 5/16" x 3/4" turn bolt into the Strongback, twist and lock into place.

B. Place Rail-to-Rail bracket onto turn bolt and align to mark on Strongback,secure with 5/16" flange nut.

Continue in this manner, installing all Rail-to-Rail brackets on remainingStrongbacks before the Power Rails.


installing

Figure 5-2: Southern & Northern Rail-to-Rail Bracket Installation

SouthernL Foot

Rail-to-RailBracket

Rail-to-RailBracket

5/16" x 3/4"Turn Bolt

5/16" x 3/4"BoltTurn

5/16"Flange Nut

5/16"Flange Nut

NS

NS

Align toMark on

Strongback

Align toMark on

Strongback



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Figure 6-1: Installing Southern and Northern Power Rails

Rail-to-RailBracket


5/16"Flange Nut N

S

Power Rail

Rail-to-RailBracket


5/16"Flange Nut

NS

Power Rail

Note RailOrientation

Note RailOrientation

Step 6: Installing Power Rails

Power Rails attach to the Rail-to-Rail brackets using 5/16" x 3/4" turn bolts andflange nuts. While installing, pay close attention to the orientation between thePower Rail and the Rail-to-Rail brackets. Additionally, refer to the job specificplans for the E-W positioning of the Power Rail along the Strongbacks. In most

cases, the run of the Power Rail is centered over the Strongbacks.

A. Position the southern Power Rail to the north side of the Rail-to-Railbrackets with the Power Rail profile in the same orientation as shown inFigure 6-1.

B. Referring to the Power Rail Design Guidelines, set the E-W position of thePower Rail in relation to the Strongbacks by following the maximumallowable spans and cantilevers required for your site conditions.

C. Insert one 5/16" x 3/4" turn bolt into the Power Rail at each location of theRail-to-Rail brackets along the Power Rail.

D. Align each turn bolt to its respective Rail-to-Rail bracket and secure with5/16" flange nuts.

Install the northern Power Rail in the same manner. (See Figure 6-1)

Torque all at 14-16 ft.-lbs.

NOTE:Turn Bolts must belocked into thechannel by rotatingclockwise 90-degrees. Use theindicator slot onthe threaded endto identify whetheror not a Turn Bolthas been locked.

Indicator Slotshown in Red

Locked

Turn Bolt shownin cStrongback

hannel of



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Installing Modules using Standard End and Mid Clamps:

Start with exterior Module and End Clamps.

A. Place Module on two Power Rails,centering it lengthwise. Use asquare to square-up the Module tothe Power Rails.

B. Insert one 5/16" x 2, 2-1/4, 2-1/2,2-3/4, or 3" carriage bolt into thetop slot of the Power Rail. Push thebolt against the side of the moduleframe. Install End Clamp onto boltand secure with 5/16" flange nut.

(SeeFigures 7-1 and 7-3)

Now install the next in-line Module using

Mid Clamps.

C. Before placing the interior Moduleonto the Power Rails, first insert5/16" x 2, 2-1/4, 2-1/2, 2-3/4 "carriage bolts (bolt length isdependent on depth of Moduleframe) into the Module Rail,sliding the bolts inward next to the previously installed exterior Module.(See Figure 7-4)


, or 3

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Figure 7-3: Installing Modules usingStandard End-Clamp

Figure 7-4: Inserting Mid Clamp Hardware into Power Rail

NOTE:If using standard5/16" carriagebolts for MidClamps, they mustbe inserted intoPower Rail beforeinstalling interiorModules.

If using RADhardware, theycan be insertedanytime at anyposition along thePower Rail.

WARNING:Modules must beheld in place untilthey are secured

at all four pointswith clampinghardware. Failureto do so couldlead to seriouspersonal injuryand/or damagedcomponents.

Slide 5/16 xCarriage Bolts intoModule Rail

Slide CarriageBolts inward,adjacentto ExteriorPV Module

ExteriorPV Module

5/16 x 2, 2-1/4,2-1/2, 2-3/4, or 3inch bolt. Lengthis dependent onModule framedepth.

**

**


Standard

End Clamp

5/16 x 2, 2-1/4, 2-1/2, 2-3/4, or 3" inch bolt.Length dependent on Module frame depth.**

P8 Power Rail

5/16"FlangeNut

5/16" xCarriage Bolt

**


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Installing Modules using RAD End and Mid Clamps:

Start with exterior Module and End Clamps.

A. Place Module on two Power Rails,centering it lengthwise. Use asquare to square-up the Module tothe Power Rails.

B. Insert one 5/16" x 2, 2-1/4, 2-1/22-3/4 " RAD bolt into the topslot of the Power Rail. Push thebolt against the side of the moduleframe and twist to lock in place.Install End Clamp onto bolt andsecure with 5/16" flange nut.

(SeeFigures 7-1 and 7-6)

Install next in-line Module using Mid Clamps.

C. Insert one 5/16" x 2, 2-1/4, 2-1/2,2-3/4 " RAD bolt (bolt lengthis dependent on depth of Moduleframe) into each Rail, next to thepreviously installed exteriorModule. Twist RAD bolt to lock inplace. (See Figure 7-7)

, or 3

, or 3


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Figure 7-5: Installing Modules usingStandard Mid Clamp

D. Install a Mid Clamp onto eachcarriage bolt making certain thatthe Mid Clamp tabs rest betweenthe two modules.

E. Push Modules against Mid Clamp

tabs and secure Mid Clamp with5/16" flange nut.

(See Figures 7-2 and 7-5)Torque to 14-16

ft.-lbs. Tabs

Pre-loadedCarriage Bolt

Push Modulesagainst Tabsof Mid Clamp

StandardMid Clamp

5/16"FlangeNut

Figure 7-6: Installing Modules usingRAD End Clamp


RADEnd Clamp

5/16" xRAD Bolt

**

5/16"Flange

Nut

Rotateto Lock

P8 Power Rail

5/16 x 2, 2-1/4, 2-1/2, 2-3/4, or 3" inch bolt.Length dependent on Module frame depth.**


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WARNING:Its very importantto support theweight of the arrayduring thisprocedure. Aminimum of twopeople should beused to hold and

support the arraywhile a thirdperson loosensand retightens thehardware. Failureto do so couldlead to seriouspersonal injuryand/or damagedcomponents andproperty.

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Step 8: Adjusting Tilt Angle with Telescoping Legs

The Telescoping Legs are designed to easily adjust the tilt angle of an array. It isrecommended that this procedure be done by a minimum of two people. Afterloosening specific hardware, the full array pivots from the southern L-Feet.

Use caution when loosening hardware to avoid disengaging them from theirlocations. Loosen just enough to allow components to rotate freely .

A. Begin by loosening the hardware attaching the Strongbacks to the L-Feet.

B. As two people hold and support the array from the backside, the third personloosens the hardware at both ends of the Telescoping Legs.

C. Now loosen the Telescoping Leg lock bolts.

D. Lift/push the array to the desired tilt angle and hold in place.

E. Re-tighten and torque hardware as follows (See Figure 8-2):

1. Two Telescoping Leg lock bolts:

2. Flange Nuts securing Legs to Strongback:

3. Hardware securing Legs to L-Feet:

4. Flange Nuts securing Strongbacks to L-Feet:

(See Figure 8-1)





Note: Letters designate loosening sequenceof hardware and matches step-by-step text on next page.

NS

A

B

B

C

Figure 8-1: Adjusting Tilt Angle



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WARNING:Be certain that allhardware hasbeen retightenedand torqued to thestated values.

Failure to do socould lead toserious personalinjury and/ordamagedcomponents andproperty.

Note: Numbers match step-by-step torque values in steps above.

NS

4

2

3

1

Figure 8-2: Retighten and Torque Hardware



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Direct Power & Water Corporation

4000-B Vassar Drive NE

Albuquerque, New Mexico 87107

USA

Telephone: 800.260.3792

Fax: 505.889.3548

Web Site: www.DPWSolar.com

E-mail: [email protected]

040412-1 2012 Preformed Line ProductsPCN

Version 1, Rev A

Preformed Line Products

(Canada) Limited

1711 Bishop St. E

Cambridge, ON N1T 1N5

Telephone: 519.740.6666

Fax: 519.740.7917

Web Site: www.preformed.on.ca

E-mail: [email protected]

lprgm 3 assembly instructions version 1 rev a

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