Everest UL 2703 User manual

ASSEMBLY INSTRUCTIONS
RESIDENTIAL ROOF SOLUTIONS
CROSSRAIL SHARED RAIL SYSTEM
USA
UL 2703 Listed System

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15
TABLE OF CONTENTS
SAFETY REGULATIONS
MATERIALS REQUIRED
BONDING AND GROUNDING
MODULE COMPATIBILITY
FIRE RATING
ASSEMBLY
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 5.0 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.
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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‘s Technical Info Page:
http://everest-solarsystems.com/en-US/technical-product-information or by contacting us directly.
In general, the following applies:
TSystems should be installed by experienced contractors licensed and qualified to perform the work with professional
workmanship and quality.
TBefore 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://everest-solarsystems.com/en-US/technical-product-information or contact us
directly.
TContractor 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:
TSafety clothing is worn such as safety helmets, work shoes, and gloves.
TWhere required, Contractor should use fall protection, scaffolding with arrestor equipment and other approved methods for
worker safety.
TContractor shall verify that they are using the most current instructions by downloading the latest version from our website or
contacting our office directly.
TModule 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.
TA copy of these instructions must be on site, and read and understood by all workers during installation.
TIn 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.
TThe 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, expressed 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://everest-solarsystems.com/en-US/technical-product-information
TThe dismantling of the system should be in reverse order of these assembly instructions.
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Safety Regulations

Rail Connector Set1
Material: aluminum
Finish: mill, dark anodized
Hardware: stainless steel
CrossRail 48-S/48/80
Material: aluminum
Finish: mill, dark anodized
CrossRail End Clamp Set1
Material: stainless steel
Finish: silver, dark
CrossRail Mid Clamp UL2703+ Set1
Material: stainless steel
Finish: silver, dark
Structural Rail Connector Set
CR 48-S
Material: aluminum
Hardware: stainless steel
M
Fi
n
Burndy WEEB Lug 8.0 + Hardware4
Or Burndy WEEB Lug 10.3 + Hardware
WEEB Lug Material: tin plated copper
Hardware: stainless steel
Shared Rail for Pitched Roof:
TUL 2703 Listed
TFast, simple installation
TNo drilling, no bonding jumpers
TPre-assembled universal module clamps with
integrated bonding
TRobust bonding rail splices
TLow part count
TAlso compatible with tile roofs using commonly
available roof hooks
All components evaluated under UL 2703 and encompassed within Everest Solar System’s UL 2703 Listing shown below
If you seek a UL Listed System, only the parts shown on this page are acceptable.
UL 2703 LISTED COMPONENTS
1Dark anodized rail must use Bonding T-Bolt and Bonding MK3 hardware.
2Use standard L-foot with third-party roof attachments and EverFlash L-foot with EverFlash Comp Flashing.
3The inverter hardware kit is not intended to replace the micro inverter ground and has only been evaluated to attach to the rail.
4For certain jurisdictions, this item is regarded as a single-use item for a UL 2703 Listed System.
L-Foot with Hardware2
Material: aluminum
Finish: mill, dark anodized
Hardware: stainless steel
Optional: Micro Inverter and Optimizer
Mounting Kit1,3
Material: stainless steel
Optional: Array Skirt
Material: aluminum
Finish: dark anodized
Hardware: stainless steel
EverFlash eComp with Slider Kit
Material: aluminum, stainless steel
Finish: silver
EverFlash qComp with Slider Kit
Material: aluminum, stainless steel
Finish: silver
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Materials Required

NON-UL LISTED COMPONENTS
Components in this section were not evaluated by UL for bonding
Optional: End Cap for CrossRail
48-S/48/80
CrossRail 48-S End Cap shown
Material: glass fiber reinforced polyamide
Optional: External Omega Cable Clip
Material: polyamide, black
Optional: HEYClip SunRunner Cable
Clip SS, S6404
Material: stainless steel
Shared Rail End Clamp with AddOn
Material: stainless steal, glass fiber reinforced
polymide
Finish: mill, black oxide
Hardware: stainless steel
CrossRail Sleeve 3”, Black
Material: UV Rated PVC
Finish: dark
Shared Rail UL2703+ Mid Clamp
with AddOn
Material: stainless steel, glass fiber reinforced
polymide
Finish: mill, black oxide
Hardware: stainless steel
Optional: Burndy Omega Clip
Material: 304 stainless steel
TORQUE SPECIFICATIONS
TM10 T-Bolts: 25.8 ft-lb (35 Nm)
TWEEB Lug 10.3: 15 ft-lb (20.3 Nm)
TM8 T-Bolts: 10 ft-lb (13.5 Nm)
TClimber Set:
M8 Allen Bolts: 11.8 ft-lb (16 Nm)
TMid Clamp UL2703+
M8 Allen Bolts: 12 ft-lb (16.3 Nm)
TAll other clamps:
M8 Allen Bolts: 10.3 ft-lb (14 Nm)
TOOLS REQUIRED
TTorque wrench (0 – 50 ft-lb)
TCordless Drill (non-impact)
T13mm Deep Socket
T15mm Deep Socket
T6mm Allen Drive (for M8 Allen Bolt)
T1/2” Socket (for lag bolt)
TMeasuring Tape
TString Line
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. Please refer to the instructions of those third party products.
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.
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Materials and Tools Required