Polar Electro PR-12 User manual

Modular.
Lighter.
Quicker.
PR-4 Ground MountRev. 01
Modular.
Lighter.
Quicker.
Installation Manual
PR-12 Ground Mount Racking Solution

READ THIS ENTIRE DOCUMENT CAREFULLY BEFORE INSTALLING
ALL REFERENCES TO PV PANELS, ELECTRICAL AND GROUNDING
INSTRUCTIONS CONTAINED IN THIS MANUAL ARE FOR
INFORMATION ONLY. CONSULT THE MANUFACTURER FOR
INSTALLATION INSTRUCTIONS
THIRD PARTY DESIGN, ANCHORING, FOUNDATION AND
INSTALLATION OF THE POLE MOUNT IS ALSO FOR INFORMATION
ONLY - ALWAYS CONSULT A PROFESSIONAL CIVIL ENGINEER

Table Of Contents
Table Of Contents
Page 3PR-12 REV01 (Release July 2014)
1. Introduction 4
1.1 Product Overview 4
1.2 About this Manual 4
1.3 Product Liability 4
1.4 Standards Compliance 4
1.5 Product Care & Maintenance 4
2. Safety Considerations 5
2.1 Basic Safety Consideration 5
2.2 Warnings 5
2.3 Responsibility of the Installer 5
2.4 Responsibility of the Operator 5
3. Preparation 6
3.1 Tools & Materials 6
3.2 Site Preparation 6
4. Installation Instructions 7
4.1 Step 1: Mount Strong Back on Top of Pole 7
4.2 Step 2: Align Strong Back 7
4.3 Step 3: Install Vertical Rails 7
4.4 Step 4: Attach Tilt Support Arms to Vertical Rails 8
4.5 Step 5: Attach Tilt Support Arms to Strongback 8
4.6 Step 6: Tilt Vertical Rails to horizontal position 8
4.7 Step 7: Install M8 Bolts in Horizontal Rails 9
4.8 Step 8: Install Horizontal Rails 9
4.9 Step 9: Install Modules on Horizontal Rails 9
4.10 Step 10: Set Tilt Angle and torque all bolts 10
4.11 Step 11: Adjust tilt angle of Array 10
Overview of PR-12 Assembly 11
Table Of Contents
Table Of Contents
Page 3

1. Introduction
1.1 Product Overview
The PR-12 Ground Mount is a versatile mounting solution for
any PV module.
Installer friendly, with fast installation times, its flexible design
allows for highly configurable solutions.
The mount is seasonally adjustable, with a 10 Year Warranty,
Fully Engineered, with full customer support for the North
American Market.
Service life Warranty
Polar provides a warranty of 10 years for the service
life of all materials used.
Safety
If a building permit is required, Polar Racking may provide a
mounting system and foundation design sealed by a
professional engineer, in the relevant jurisdiction at an
additional cost. It is the sole responsibility of the
Owner/Installer to determine and qualify that the mounting
system affectively meets the local building code(s) and site
specific conditions.
1.2 About This Manual
Subject
This manual details the installation and assembly of the Polar
PR-12 Top of Pole Ground Mount.
Target Audience
This manual is intended for qualified personnel with a
working knowledge of mechanics, hand tools and one who
possesses mechanical skills.
Signposts
The following will assist you in finding your way around in this
manual:
Headers
The headers display the heading of the current chapter.
Footers
The footers display the product name, the name of the
document, and the page number.
1.3 Product Liability
This technical documentation is part of the product.
Polar Racking is not liable for damages resulting from failing
to comply with the installation instructions, particularly
the safety instructions, as well as misuse of the product.
All Polar Racking products are designed and manufactured
to comply with international standards (refer to the product
label for details). As the conditions or methods of installation,
operation, and maintenance are beyond Polar Racking’s
control, Polar Racking Inc. does not assume responsibility
and expressly disclaims liability for loss, damage or expense
arising out of, or in any way connected with, such installation,
operation, use or maintenance.
1. Introduction 1.1 Product Overview
Page 4PR-12 REV01 (Release July 2014)
1.5 Product Care and Maintenance
Maintenance periods
Checks & procedures should be carried out immediately after
installation, then at 3 days and 21 days. (With annual
inspections thereafter)
- Ensure all Modules are properly clamped.
- Check angle of modules.
- Ensure all Bolts are torqued to correct specification.
- Ensure mount is facing South.
- Ensure no movement due to rotation or vibration.
1.4 Standards Compliance
The PR-12 Ground Mount is 100% OPA Compliant and is
tested in accordance with the NBCC and the Ontario
Engineering Standards Guide for Structures.

2. Safety Considerations 2.1 Basic Safety Considerations
Page 5PR-12 REV01 (Release July 2014)
2.1 Basic Safety Considerations
The following basic safety instructions and warning notes are
an essential part of this manual and are of fundamental
importance for handling the product.
2.2 Warnings
Throughout this manual you will notice several warning notes
which consist of
• Warning Symbols
• Indicator Words to dictate the danger Level
• Information regarding the source and type of the danger
• Information about possible consequences if the hazard is
not observed
• Measures for avoiding the hazard, and ways to prevent
injuries or property damages
Danger
Denotes a major risk. Failure to observe may lead
to serious injury or death
Warning
Denotes a potentially dangerous situation.
Failure to observe may lead to moderate to severe
injury and/or property damage
Caution
Denotes a potential hazard which may lead to
physical injury and/or property damage
2.3 Responsibilities Of The Installer
It is the sole responsibility of the installer to ensure that all
applicable safety measures are strictly adhered to while
installing this 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 all 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.
2.4 Responsibilities Of The Operator
It is the sole responsibility of the operator to ensure that all
scheduled maintence is performed on time. He/She must
ensure that the installation of the system is performed only by
qualified personnel with adequate skill and knowledge.
The operator must ensure that a copy of this manual is
available to any installer and/or maintenance person as it is
part of the system. A replacement manual may be obtained
by contacting Polar Racking using the contact information
provided on the back of this manual.
2. Safety Considerations
DO NOT attempt any installation in adverse weather
conditions (when high winds, rain, ice or snow is present).
Remove any jewelery or other metallic adornments to avoid
accidental electrical contact and use insulated tools.

3. Preparation 3.1 Tools and Materials
Page 6
3.1 Tools & Materials
Tools required for typical Installation
1) Extendable ladder.
2) Lifting Device. (Capable of lifting 3000lbs)
3) A set of standard Metric Open End or Adjustable
Wrenches
4) A set of standard Metric Hex Keys
5) T-Square or framing square and a hand held drill
6) Torque Wrench (up to 150 ft lbs) and battery
powered drill with 10mm Chuck.
3. Preparation
3.2 Site Preparation
Prior to beginning installation ensure the following:
1) All safety preparations have been made in
compliance with local regulations
2) All required tools and materials are available for the
installation
3) All loose debris and any potential safety hazards
have been removed from the installation area
4) All the installers have copies of relevant installation
manual and drawings
3. Preparation
Page 6
PR-12 REV01 (Release July 2014)
3.1 Tools & Materials
Tools required for typical Installation:
1) Extendable ladder.
2) Lifting Device. (Capable of lifting 3000lbs)
3) A set of standard Metric Open End or Adjustable
Wrenches
4) A set of standard Metric Hex Keys
5) T-Square or framing square and a hand held drill
6) Torque Wrench (up to 150 ft lbs) and battery
powered drill with 10mm Chuck
3. Preparation
3.2 Site Preparation
:
1) All safety preparations have been made in
compliance with local regulations
2) All required tools and materials are available for the
installation
3) All loose debris and any potential safety hazards
have been removed from the installation area
4) All the installers have copies of relevant installation
manual and drawings

A compass with a square edge can be used to initially locate
MAGNETIC North / South. Place the compass on the flat
plate at the top of the strong back. As the U-Bolts are not fully
torqued, manually adjust to the required North / South
orientation.
Torque Hex Nuts to 110ft lbs or 149 Nm, this should be done
when the final orientation of the array is established.
4.2 Step 2
Place Six(6) Vertical Rails into the Clevis Supports on the
Strong Back Weldment. Install each Vertical Rail with One
M10 x 90 Hex Head Pivot Bolt, Two M10 Flat washers, One
M10 Split Lock Washer and One M10 Hex Nut. Lightly tighten
the M10 x 90mm Hex Head Bolts. (Torque to 37 ft lbs or
50Nm after mounting of modules and setting the desired tilt
angle shown in Step 11).
For the Polar PR-12 Top of Pole application, Lift strong back
onto pole and install Three U-Bolts, each with Two 1/2” Flat
Washers, Two 1/2” Split Lock Washers and Two 1/2” Hex
Nuts. Leave nuts finger tight to allow for adjustment.
4.1 Step 1
4. Installation Instructions
4.3 Step 3
4. Installation Instructions
4. Installation Instructions 4.1 Step 1
Page 7
PR-12 REV01 (Release July 2014)

Attach One Tilt Support Arm to the Two Inner-most Vertical
Rails With One M10 x 90 Hex Head Pivot Bolt (Ensure T-Slot
is oriented upwards). Each Bolt attaches with Two M10 Flat
washers, One M10 Split Lock Washer and One M10 Hex Nut
(Torque to 37ft lbs or 50Nm after mounting of modules and
setting the desired tilt angle shown in Step 11).
4.4 Step 4 4.5 Step 5 4.6 Step 6
Attach each Tilt Support Arm to the Strong Back Lower
Support Arm Clevis with One M10 x 90 Hex Head Pivot Bolt
as shown in Fig.3.
Each Bolt attaches with Two M10 Flat washers, One M10
Split Lock Washer and One M10 Hex Nut as shown in Fig.3.
(Torque to 37ft lbs or 50Nm after mounting of modules and
setting the desired tilt angle shown in Step 11).
For larger arrays (up to PR20) with multiple Vertical Rails
install one Horizontal Rail to the Vertical Rails (See Step 8), to
enable the tilting of ALL Vertical Rails to a horizontal postion.
Insert an M8x16mm socket head bolt with ribbed lock washer
through each of the holes in the Horizontal Rail and
assemble square nuts, as shown in Fig. 4 above.
Slide the Horizontal Rail onto the Vertical Rails and loosely
tighten the bolts. (Enough so that all Vertical Rails will tilt
simultaneously when Tilt Arms are pushed forward).
4. Installation Instructions
4. Installation Instructions
Page 8
4.4 Step 4
4. Installation Instructions
4. Installation Instructions
Page 8
4.4 Step 4
PR-12 REV01 (Release July 2014)

Loosen the M8 Bolt located in the Tilt Clevis as shown in
Fig.5. to tilt the vertical rails to a horizontal position and
tighten to hold the position.
When the Vertical Rails have been tilted to the horizontal
position, the Horizontal Rail attached in Step 6 can be
loosened and adjusted to required position (Step 8).
Insert an M8x16mm socket head bolt with ribbed lock washer
through each of the holes in the Horizontal Rails and
assemble square nuts, as shown in Fig 6. (4 Rails in total).
As modules are slid onto the rails (Step 9), torque the bolts in
the horizontal Rails to 18ft lbs or 25Nm, first, before modules
cover these bolts. This ensures that the rails are square.
Slide on and loosely tighten the Horizontal Rail(s) closest to
the centre pivot point first. Install Outer Horizontal Rail(s) next
and keep loose to slide on first Module.
Orient 4 rails as shown above with centre rail(s) as close to
pivot point as possible.
All rails should be left loose until modules are installed to
ensure squareness.
4. Installation Instructions
4.7 Step 7 4.8 Step 8 4.9 Step 9
5A Fuse
4. Installation Instructions
Page 9
4.7 Step 7
4. Installation Instructions
Page 9
PR-12 REV01 (Release July 2014)
4.7 Step 7
INSERT M8 BOLT
ASSEMBLY INTO
HORIZONTAL RAILS AND
SLIDE HORIZONTAL
RAILS ONTO VERTICAL
RAILS (STEP 9)

Loosely mount M6x16mm Socket Head Bolts (Depending on
module type), Flat Washers, Split Lock Washers and Square
Nuts onto each PV Module Mounting Hole, then slide Module
onto the Horizontal Rails. As modules are slid onto the rails,
torque the bolts in the horizontal Rails to 18ft lbs or 25Nm,
first, before modules cover the bolts. This ensures rails are
square. (Ensure a spacing of 6mm between all Modules)
When Module is positioned correctly, torque each bolt to
18ft lbs or 25Nm.
Loosen the M8 Bolt located in the Tilt Clevis and Slide the Tilt
Clevis to adjust the Array to the desired angle.
(Once tilt is set, Torque M8 Bolt to 37 ft lbs or 50Nm)
Torque Tilt Support Arms & Main Pivot Bolts to 37 ft lbs or
50Nm.
Ensure ALL connections are tightly secured and Torqued to
correct specification.
4.11 Step 11
4. Installation Instructions
Page 10
4.10 Step 10
4. Installation Instructions
LOOSEN M8
BOLT
4.10 Step 10
4. Installation Instructions
Page 10
4.10 Step 10
4. Installation Instructions
PR-12 REV01 (Release July 2014)