evergreensolar ES-A Series Installation instructions manual

ES-A Series Photovoltaic Panels
Mounting Guide (including PanelClaw™)
ELECTRICAL EQUIPMENT — CHECK WITH YOUR INSTALLER
Evergreen Solar ES-A Series photovoltaic (PV, solar electric) panels are designed to produce DC electrical energy from light.
This manual contains important installation information with which you should be familiar before using Evergreen Solar panels.
This Guide is valid in North America only
(ETL listed; conforms to UL Standard 1703)
PanelClaw is a registered trademark of PanelClaw, Inc. SM-0050revA

ES-A Series Photovoltaic Panels
Mounting Guide
www.evergreensolar.com
MG-ES-A_US_011209_ETL © 2009 Evergreen Solar, Inc.
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Worldwide Headquarters
Evergreen Solar Inc.
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T: +1 508.357.2221
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[e-mail]
Customer Service - Americas and Asia
Evergreen Solar Inc.
138 Bartlett Street
Marlboro, MA 01752 USA
T: +1 508.357.2221
F: +1 508.229.0747
[e-mail]
SM-0050revA
Due to continuous innovation, research and product development, the guidelines in this Mounting Guide
are subject to change without notice. No rights can be derived from the Mounting Guide and Evergreen
Solar assumes no liability whatsoever connected to or resulting from the use of any information contained herein.
Introduction
This guide is designed to make using Evergreen Solar panels as easy as possible by providing a comprehensive
range of installation options.
It is also designed to give you clear instructions on how to install Evergreen Solar panels to ensure compliance with
all major certification and regulatory requirements as well as Evergreen Solar warranty requirements.
All guidelines in this document apply to ES-A Series products manufactured by Evergreen Solar. They do not
apply to any other products manufactured by Evergreen Solar or any product manufactured by another company.
ES-A Series products not installed according these guidelines will void the warranty.
Three major methods of mounting ES-A Series solar panels are described in this guide:
Method A: Support rails or support points located symmetrically under the panel
Method B: Three support rails installed under the panel
Method C: Independent support points located asymmetrically under the panel
Each configuration has a maximum combined wind and snow loading associated with it that is guaranteed by
Evergreen Solar. Panels can be mounted in either a horizontal or vertical orientation providing one of the approved
mounting methods is used.
The mounting system vendors’ installation instructions must always be strictly followed and in cases where the
mounting system vendor either:
a) Does not allow a particular configuration which is permissible according to this guide, or
b) Does not allow wind or snow loads as high as described in this guide
Then the mounting vendors’ installation instructions must take precedence over these guidelines. In any cases of
doubt the mounting vendors’ installation instructions should always take precedence.
In addition, you should always consult with your local authorities for stricter regulations which may apply in your
particular area or to the particular structure you are attaching Evergreen Solar panels to.
For additional information please read the Safety, Installation and Operation Manual provided by Evergreen Solar
and available upon request.
We wish you every success in using Evergreen Solar product.

(A1)
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Mounting Guide
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Mounting Method A
Support rails or support points located symmetrically under the panel
Configuration Options
Three symmetrical mounting configurations are permissible, as shown in Figure 1 below: (A1) Short-side end
mounting, (A2) Offset mounting, and (A3) Long-side end mounting.
Support rail
is flush along
short side of panel.
Support rail is
flush along short
side of panel.
Short-sideShort-side
Long-side
Panel length (65 in.)
Figure 1: (A1) Short-side end mounting, (A2) Offset mounting and
(A3) Long-side end mounting
Panel width (37.5 in.)
Support rail
A1. Short-side End Mounting
Short-side end mounting (Figure 2) uses two support rails installed under the outer edges of the panel frame (on
the short sides) that run flush along the entire panel width.
(A1)
(A2)
(A3)
Figure 2: Short-side end mounting

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Short-side end mounting is guaranteed to a maximum combined wind and snow load of 40 lbs/ft2. Three end
mounting options are permissible as detailed below:
Option A1.1 – Rigid Rail Supports
Rigid rails spanning the entire panel width must support the short-sides of the panel. The rail area directly in
contact with the panel frame must be at least ¾ in. wide. Topside clamps must be used to secure the panel in
place and must overlap at least 1 /5in. of the frame top surface. Three different topside clamp configurations
may be used as follows:
Clamp Arrangement A1.1a
The short sides of the panel may be clamped along the entire frame top surface as shown in Figure 3.
1
/5in. minimum overlap of
clamp onto frame top surface
Clamp Arrangement A1.1b
The short sides of the panel may be clamped at the corners using a top-side clamp shared by adjacent
panels. Since Evergreen Solar recommends a minimum ¼ in. gap between panels, the clamp should be at
least 2¼ in. long to ensure each panel frame is clamped by at least 1 in.
1 in. clamping distance over
each panel frame top surface
1
/5in. minimum overlap of clamp
onto frame top surface
1
/5in. minimum overlap of
clamp onto frame top surface
1 in. minimum
3 in. maximum
Figure 3: Clamping along the complete length of the panel short-side
Figure 4: Clamping adjacent panel frames
Clamp Arrangement A1.1c
The short sides of the panel may be clamped by two top-side clamps which are not shared by adjacent
panels. Each clamp must be at least 1 in. long and the entire clamp must be positioned within 3 in. from the
nearest panel corner.
Figure 5: Clamping each panel frame individually
Support rail
Support rail
2¼ in. minimum

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Allowable
Mounting
Area
Allowable
Mounting
Area
Mounting
Not
Allowed
1 in. minimum
A2. Offset Mounting:
For the offset mounting configuration the first mounting rail – installed on either the left or right side of the panel
– must be installed within the allowable mounting area (i.e. within 21.7 in. of each short side edge). The second
rail must be located at the same distance from the opposite short edge of the panel.
There are 4 sections (I, II, III and IV) within the allowable mounting area that correspond to different maximum
combined wind and snow loads. The location of each section is shown in Figure 8.
Option A1.2 – Clamp-Based Supports Only
The short sides of the panel may also be supported and clamped at each corner without using support rails in
direct contact with the frame. Each corner clamp must be at least 1 in. long and clamp both the top and bottom
surfaces of the frame over a distance of at least 1 in. The entire clamp must be positioned within 1¾ to 3 in. of the
panel corner.
Figure 6: Clamping each
panel without rails in direct
contact with the panel
Figure 8: The location of
different sections in the
allowable mounting area
13.0 in.
16.3 in.
21.7 in.
13.0 in.
All lengths are specified with
a tolerance of +/- 1 in.
1/5 in. minimum overlap
of clamp onto frame
top surface
3 in. maximum, 1¾ in. minimum
Option A1.3 - PanelClaw™attachment system
This method uses a special clamp, called a “claw”, designed to attach to the flange of the frame. The claw (P/N 191-
001) is manufactured by PanelClaw, Inc. and is exclusively used in their mounting systems. Four claws are required
per panel; one on each corner. Place claw over flange and tighten the 3/8-16 x1.25” SHCS 18 – 8 S/S screw between
18 to 20 ft-lb. Ensure the claw is flush with both the long and short lengths of the panel flange as shown in Figure 7.
Figure 7: PanelClaw™
attachment system
Claw is flush with both the
long and short lengths
of the panel flange
I
II
III IV I
II
IV III

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III III IV
Allowable
Mounting
Area
Allowable
Mounting
Area
Mounting
Not
Allowed
Panel length (65.0 in.)
I
II
III IV I
II
IV III
Offset Mounting continued
Figure 9 illustrates the maximum permissible combined wind and snow loads for sections I, II, III and IV. Support
rails at section II allow the highest maximum loading of 60 lbs/ft2. Support rails located anywhere in sections I
and III allow a maximum of 40 lbs/ft2and 50 lbs/ft2respectively.
Figure 9: Maximum permissible combined wind and snow loads by rail location
60
40
lbs/ft2
For offset mounting only one clamping configuration is permissible as shown in Figure 10. At least two rigid
support rails must span the entire panel width and topside clamps must be used to secure the panel to the rails.
Clamps must be at least 1½ in. wide and the rail area supporting the panel must be at least ¾ in. wide.
¾ in. minimum width
1
/5in. minimum overlap of
clamp onto frame top surface
Figure 10: Permissible clamp arrangement for offset mounting
Offset Mounting using the frame holes
Mounting holes with a diameter of ¼ in. are also provided in the panel frame at the 1 /5and ¼ points. These
points are located on the long-sides of the panel at 13.0 in. and 16.3 in. respectively from the short-sides of the
panel; all four mounting holes must be used when mounting a panel using the frame holes and the maximum
combined wind and snow loadings for offset mounting apply at these locations.
Support rail
Support rail
1½ in. minimum width
13.0 in.
16.3 in.
21.7 in.
13.0 in.
All lengths are specified with
a tolerance of +/- 1 in.
50

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Figure 11: Long-side end mounting
This method is guaranteed to a maximum combined wind and snow load of 80 lbs/ft2. Rigid rails spanning the
entire panel length must support the long-sides of the panel. The rail area directly in contact with the panel
frame must be at least 3/4in. wide. Panel must be clamped along the entire frame top surface, as shown in
Figure 11 above. Minimum overlap of clamp onto top surface must be 1/5in.
11 /2 in. Width Minimum
Figure 12: Permissible clamp arrangement for three support rail mounting
A3. Long-Side End Mounting
Long-side end mounting uses two support rails installed under the outer edges of the panel frame (on the long
sides) that run flush along the panel length.
1/5 in minimum overlap
of clamp onto frame
top surface
Panel length (65 in)
Support rail is flush
along the long side
of the panel
Panel width (37.5 in)
Mounting Method B
Three Support Rails Installed Under the Panel
Mounting Method B uses three support rails installed under the long sides. The permissible clamp arrangement
for three support rail mounting is shown in Figure 12 below. Rails run parallel to the short sides making contact
with the back side of the frame and secured with 6 top mounting clamps. Two of the rails must be installed at the
1/5 points (13 in. from the end) and the third one at the center. Rail area supporting the panel must be at least 3/4
in. wide. Clamps must be at least 1.5 in. wide and minimum overlap onto the frame top surface must be 1/5 in.
This method is guaranteed to a maximum combined wind and snow load of 80 lbs/ft2.
1
/5 in. Minimum overlap
of clamp onto
module top surface
3
/4 in. Width
Minimum
13” ±1”
13” ±1”
32.5” ±1”
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Mounting Method C
Independent support points located asymmetrically under the panel
Mounting method C uses point supports under the panel frame instead of continuous rails. The point supports
can be asymmetrically located under the panel as long as the guidelines detailed below are followed.
The spacing and location of the point supports is designed to allow direct mounting of panels to 24 in.-
spaced roof rafters. This mounting method is guaranteed to a maximum combined wind and snow load of
40 lbs/ft2for any configuration option.
Configuration Options
Two configuration options are permissible – one with four support points per panel and one with six. Each
support point must be at least 1½ in. wide (see Figure 13) and must support the entire width of the frame
flange (see Figure 14). Top side clamps must be used to secure the panel in place; each top-side clamp must
be at least 1½ in. wide, and must overlap at least 1/5in. of the frame top surface.
1½ in. minimum clamp width
1½ in. minimum point support width
Figure 13: Point support and clamp requirements
1
/5in. minimum overlap of
clamp onto frame top surface
Figure 14: Location of point support in relation to the panel frame
Frame flange
Point support
Glass
Point support must support
entire width of frame flange

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Figure 15:
Required support
locations for the 4
point option
Option C1 – Four Supports
Four supports can be used to support the panel, positioned as shown in Figure 15. Two supports must be positioned
under each half of the panel, and supports on opposite sides of the panel must be in line with each other.
The first set of supports, installed on either the left or right side of the panel, must be installed between 15.5
and 25.5 in. from the short-side edge of the panel. The second set of supports must be located at a distance
of 24 in. (+/- 1 in.) from the first set of supports.
Panel center linePanel length (65 in.)
At least two support
points must lie in each
half of the panel
Panel width
(37.5 in.)
Location of
point supports
24 in. +/- 1 in.
Panel length (65 in.)
Panel width
(37.5 in.)
24 in. +/- 1 in.
<=15.5 in.
Figure 16:
Required support
locations for the 6
point option
Option C2 – Six Supports
Six supports may be used to support the panel, positioned as shown in Figure 16. At least two supports must be
located under each half of the panel, and supports on opposite sides of the panel must be in line with each other.
The first set of supports, installed on either the left or right side of the panel, must be installed between 0 and
15.5 in. from the short-side edge of the panel. The second set of supports should be located at a distance of
24 in. (+/- 1 in.) from the first set of supports and the third set of supports should be located 24 in. (+/- 1 in.)
from the second set of supports.
24 in. +/- 1 in.
Support points
on opposite
sides of the
panel must
be aligned
Panel center line
15.5 in. min, 25.5 in. max
At least two
support points
must lie in each
half of the panel
Support points
on opposite
sides of the
panel must
be aligned