Polar Electro PRG User manual

PRG_Install Manual_Release_008
March 26, 2019
PRG INSTALLATION MANUAL
UL2703 Listed for Bonding and Grounding
Fire rated for use with Type I and II
Modules on Class A roofing Materials
CSA LTR AE-001:2012 Classified for
Bonding and Grounding

2
Table of Contents
Table of Contents............................................................................................... 2
1. Safety UL 2703 and CSA LTR AE-001:2012............................................. 3
2. Parts and Tools....................................................................................... 4
3. Storage and Handling............................................................................. 7
4. Racking Overview................................................................................... 8
5. Racking System Installation Instructions ............................................. 10
6. Grounding Instructions ........................................................................ 19
7. Side Shield Instructions........................................................................ 23
8. Optimizer/Micro Inverter Installation ................................................. 25
9. Anchor Bracket Installation.................................................................. 26
10. Appendices.......................................................................................... 27
Appendix 10.1 (Solar Module Compatibility)...................................... 27
Appendix 10.2 (Ballast Stones, Specifications, Installation) ............... 28
11. Warranty and Product Maintenance………………………………………………..29

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1. Safety, UL 2703 and CSA LTR AE-001:2012
Basic Safety Considerations
The following basic safety instructions and the warning notes are an
essential part of this manual and are of fundamental importance for
handling the product and its conformity to UL.
Warnings
Throughout this manual you will notice several warning notes which consist
of:
•Warning Symbols
•Information regarding the source and type of the danger
•Measures for avoiding the hazard, and ways to prevent injuries or
property damages
Caution
Denotes a potential hazard which may lead
to damage to racking, physical injury and/or
property damage
Visually Inspect
Denotes a manual inspection process must
take place before proceeding with the
installation.
Check and Compare
Denotes that the installer must check the
installation on site and compare it to the
image before proceeding.
Responsibilities Of The Installer
It is the responsibility of the installer to ensure all applicable safety measures are
strictly adhered to while installing this PV Racking system. Any modifications are to
be performed only by authorized personnel and must be approved by Polar Racking
prior to implementation. The installer must have adequate skill and knowledge with
any materials and tools used to install this system.
Furthermore, the installer must be able to recognize any possible dangers, whether
they are stated in this manual or not. Every person installing this system must read,
and fully understand, every section of this manual prior to working on the system.
Responsibilities Of The Operator
It is the responsibility of the operator to ensure all scheduled maintenance is
performed on time. He must ensure that the installation of the system is performed
only by qualified personnel with adequate skill and knowledge. The operator must
ensure a copy of this manual is available to any installer and/or maintenance person
as it is part of the overall system. A replacement manual may be obtained by
contacting Polar Racking through our website at www.polarracking.com.
UL 2703 Conformance
The PRG system is rated under UL 2703/ULC ORD 1703 by following the below
guidelines.
The racking system has been designed to be installed over a fire resistant roof
covering with a class A rating only.
The racking system is to be used with ballast stones as a primary means of
securement to roofing structure. See layout for site ballasting information.
The racking system may be used to ground and/or mount a PV module complying
with UL 1703 only when the specific module has been evaluated for grounding
and/or mounting in compliance with the included instructions.
The racking system has been tested to withstand downward pressures up to 50 PSF,
upward pressure of up to 5 PSF and down-slope loads of up to 5 PSF.
CSA LTR AE-001:2012 Conformance
The PRG system is rated under CSA LTR AE-001:2012 by following the below
guidelines. Photovoltaic Racking System Installed using PRG March 26, 2019.

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Sockets:
13mm Deep Socket with ½” Drive
8mm Socket with ½” Drive
2. Parts and Tools
Tools
Power Drill with
½” Socket Drive Adapter Calibrated Torque Wrench with ½” Drive Tape Measure
13mm Wrench Chalk Line Level Approved Construction Layout

5
System Components
Number
Description
Image
Part #
1.
Right Hand
Runner
300106001-5°
300228001-5°
300107001-10°
300209001-10°
300108001-15°
2.
Left Hand
Runner
300109001-5°
300229001-5°
300110001-10°
300210001-10°
300111001-15°
3.
North
Clamp/
Cross
Member
Clamp
300102001
300199001
300227001
4.
South
Clamp/
Accessory
Bracket
300103001
300198001
5.
Top Clamp
300104001 - 31-35mm
300104002 - 37-40mm
300104003 - 43-46mm
300104004 - 47-50mm
300104005 - 26-30mm
6.
Rubber
Mat
500068001
7.
Wind
Deflector
300124001 - 15°/1954-1972mm
300124002 - 15°/1639-1660 mm
300124003 - 10°/1954-1972mm
300124004 - 10°/1639-1660 mm
300124005 - 5°/1954-1972mm
300124006 - 5°/1639-1660 mm
300124007 - 15°/2001-2018 mm
300124008 - 10°/2001-2018 mm
300124009 - 5°/2001-2018 mm
300124010 - 15°/2019-2036mm
300124011 - 10°/2019-2036mm
300124012 - 5°/2019-2036mm
300124013 - 15°/1982-2000mm
300124014 - 10°/1982-2000mm
300124015 - 5°/1982-2000mm
300124016 - 15°/2050-2067mm
300124017 - 10°/2050-2067mm
300124018 - 5°/2050-2067mm
Number
Description
Image
Part #
8.
Cross Member
300188001 - 5°/1639-1660 mm
300188002 - 5°/1954-1972mm
300188003 - 5°/1982-2000mm
300188004 - 10°/1639-1660 mm
300188005 - 10°/1954-1972mm
300188006 - 10°/1982-2000mm
300188007 - 15°/1639-1660 mm
300188008 - 15°/1954-1972mm
300188009 - 15°/1982-2000mm
300188010 - 5°/2000-2018mm
300188011 - 10°/2000-2018mm
300188012 - 15°/2000-2018mm
300188013 - 5°/2018-2036mm
300188014 - 10°/2018-2036mm
300188015 - 15°/2018-2036mm
300188016 - 5°/2050-2067mm
300188017 - 10°/2050-2067mm
300188018 - 15°/2050-2067mm
9.
Ballast Bracket
300115001
10.
Grounding Lug
400007001
400023001
11.
Side Shield
300163001 - 5°/Right
300163002 -10°/Right
300163003 -15°/Right
300164001 -5°/Left
300164002 -10°/Left
300164003 -15°/Left
12.
Side Shield
Connection
Bracket
300165001- 5°
300165002-10°
300165003-15°
13.
J Hook
900235001
14.
Roof Anchor
Connection
Bracket
(Optional)
200312001
15.
Ballast Substrate
(Optional)
500014015

6
Hardware
Number
Description
Image
Part #
1.
M8 Cap Screw,
35mm Long
100018011
2.
M8 T-Bolt,
25mm Long
100075001
3.
M8 Hex Nut
100017003
4.
M6 Trilobular
Screw,
12mm Long
100074002

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3. Storage and Handling
Site Handling and Storage
The following conditions must be met for proper onsite handling and storing of the product to avoid damage to product or roof prior to installation:
•All boxes and components delivered to site should be kept dry and under cover,
•Do not stack anything on racks or pallets of components,
•Lift pallets from designated handling areas,
•Contractors are responsible to make sure all OSHA guidelines and/or local guidelines are followed including the state regulations.
•Any and all parts removed from packaging must be visually inspected for any damage or before its use in installation
•Installer is not to use any damaged parts on the installation site. Any and all damage must be reported to Polar Racking immediately.
Annual Maintenance
The maintenance work described below must be performed once every year from the date of installation until the site is decommissioned and product is
removed from the roof.
•Inspect all fasteners and component connections. Observe for any deformation, cracks, penetrating corrosion or other defects on the PRG components and
immediately replace if deemed necessary.
•Check bolts and all hardware for specified torque (or torque marks) and re-tighten if required while ensuring all solar modules are seated correctly.
•Ensure runners are retained within grooves of rubber mats. Check all rubber substrates located under each set of ballast stones. Adjust to original installed
condition if necessary.
IMPORTANT NOTE: Due to the properties of mating fasteners, please ensure the limiting speed of cordless drivers (RPM) is set to the lowest setting and
does not exceed 3500 RPM. All fasteners provided by Polar Racking have been pre-treated to prevent material corrosion, however, this is highly dependent
upon the speed at which they are fastened.

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4. Racking Overview
1. Right Hand Runner
2. Left Hand Runner
3. North Clamp
4. South Clamp
5. Top Clamp
6. Rubber Mat
7. Wind Deflector
8. Cross Member
9. Ballast Bracket
2
1
3
4,5
,55
7
6
8
9

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Drawing Map - Sample Layout:
1Array Layout and Ballasting Information 2Project and Configuration Specific Notes
3Project Details / Names / Titles 4Ballasting Information
5Racking Critical Dimensions 6 Array Information
2
1
3
4
5
2
6

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5. Racking System Installation Instructions
Step 1: Place the first right and left hand PRG runners down.
Space them approximately 3’ apart from each other (Refer to
section 9, step 1 if achors are required)
Step 2: Position runners in grooves of rubber mats.
3’

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Step 3: Align arrows (shown) on clamps towards north and clip them on runners. Ensure tabs on clamps match into runner holes. Loosly attach with
M8x35mm. Torquing instructions in Step 8.
Installation of North Clamp
Installation of South Clamp

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Step 4: Where required, install cross members between each runner as per ballasting plan. Additonal north clamps are used to connect the cross member
to the midspan of the runners. Ensure tabs in clamps align to holes in runners, and install M8 x 35 fasteners. Torque to 7-9 ft-lbs
Installation of Cross Member
Installation of Cross Member hardware
M8 x 35 fasteners, torque to 7-9 ft-lbs

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Step 5: Following Steps 1 through 4, layout entire first row and start building columns. Connect flanges as shown below. Use M8 x 35mm fasteners at
connection points.
Install first rows and columns
A-Connection at East-West Row Ends
Torque 12-14 ft-lbs
C-Connection at North-South column end
Torque 12-14 ft-lbs
C
B
A
.
Flanges marked Left (L) and Right (R)
with alignment features
Left flanges are placed within right
runners as shown
Loosly connect hardware and adjust
alignment if necessary
B-East-West, North-South ‘X” connection
Torque 12-14 ft-lbs

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Step 6: Continue steps 1 through 5 to install remainder of array base
structure and place rubber mats as shown.
Check array for straightness about each chalk line and adjust if
necessary. Visually inspect the system for any defects or
inconsistencies. Loosen connections if required, re-align, and re-
torque runner connections to 12-14 ft-lbs.
Visually inspect alignment. Use string lines
on each row to improve installation
alignment.

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Step 7: Torque and inspect all clamps ensuring tabs are seated in runner holes, and aligned vertically to each other. Torque all south clamps to 7-9 ft-lbs and
north clamps to 4-5 ft-lbs.
Clamp tabs seated in runner holes
Check clamps are straight and no gaps between
mating surfaces
North Clamp torque to 4-5 ft-lbs
South Clamp torque to 7-9 ft lbs

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Step 8: Ballast brackets and ballast stone installation.
Position ballast bracket over cross member and engage
with tube. Install optional rubber substrate if required.
Install ballast blocks ensuring they maintain a snug fit on
brackets. Refer Appendix 10.2 for more information.
Continue ballasting remaining array.

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Step 9: Module Installation and Clamping
Loosly assemble top clamp
Insert into south clamp slot
Place module on to shoulder of
north clamp and slide into slot
Ensure module frame is fully seated
Check alignment of modules and
center within each bay
Slide top clamp assembly on to
frame and torque nut to 8-10 ft-lbs
Note: Ensure module installation is done on a per module basis. No modules shall be left unattended/unattached
without wind deflectors for an extended period of time or during inclement weather.

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Step 10:Install wind deflectors by aligning holes on deflectors with pre-punched holes on runners. Hemmed/folded edge should be facing down. Align
securing holes and place M6 Trilobial screws and secure to runners. Torque to 4-5ft-lbs (50-60 in-lbs).
Note: Ensure that wind deflectors are fully installed and/or secured during installation due to risk of damage and/or injury in high winds.
M6 Triolobial screws torque to 4-5 ft lbs
(50-60 in-lbs).
Do not over-torque. Use power tools at
the lowest torque and speed settings
Hemmed/folded edge
facing down

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6. Grounding Instructions
Note: A UL 467 approved grounding lug must be used with the PRG racking system to conform to the UL 2703 Electrical rating. Each sub array requires a means of
grounding.
Installer is responsible for and shall provide an appropriate method of direct-to-earth grounding in accordance with the latest edition of the Canadian
Electrical Code Part 1, CSA 22.1 Safety Standard for Electrical Installations or the National Building Code, including NEC 250: Grounding and Bonding, and NEC
690: Solar Photovoltaic Systems.Please refer to your local Building and Electrical Codes.. The system is rated to a maximum fuse size of 30 A.
Step 1: A Wiley WEEB 8.0 grounding lug should be connected at any outside rack flange connection point. The M8 x 35 hardware can be used for connecting to the
rack. Torque hardware to 12 ft-lbs.

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Step 2: Attach a single #6 or #8 AWG 105 °C copper wire grounding lug. Tighten the grounding lug to 5 ft-lbs.
Keep Copper away from steel components in a fashion that maintains a minimum of ¼” separation.