Tamarack Solar LTP HW Mount Series User manual

LTP HW Mount Series
Installation
Manual
LTP LCR/124HW HLK MAN 2020 Edition v2.1
For Model:
LTP LCR/124HW Top of Pole Mount
With added High Load Kit
NOTE: When adding this High Load Kit to the LTP LCR/124HW top of pole mount, use this
manual for assembly and disregard the manual that comes with the main mount kit.

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Purpose
This instruction manual, and the associated parts listed, is to be used as a replacement for the
instruction manual that came with the LTP LCR/124HW pole top mount kit. When installing the LTP
LCR/124HW with this High Load kit, disregard the instruction manual that came with the basic mount
and follow the instructions in this manual.
Table of Contents:
Introduction
The LTP LCR/124HW Top of Pole Mount with added High Load Kit is an extremely sturdy, universal pole
mounting solution designed for mounting six 60 or 72 cell solar photovoltaic (PV) modules (41 module
width maximum) With its user adjustable angle settings (0° to 60° in 10° increments), the Top of Pole
Mount can support installations in a wide range of locations.
Customer Support
Tamarack Solar makes every effort to ensure your mounting kit is easy to install. If you need assistance
at any point in your installation or have suggestions on how we can improve your experience, call
technical support at 1 800 819 7236 ext. 556 or email us at [e-mail]
Introduction...... 1
Customer Support .. 1
Tools Required ................ 2
Components List ........................................................................................................................................... 2
Step 1: Pre Assembling the Aluminum PV Module Support Rails ................................................................ 4
Step 2: Pre Assembling the Galvanized Steel Cross Rails ............................................................................. 6
Step 3: Pre Assembling the Aluminum Upper Cross Rail ............................................................................. 8
Step 4: Connecting PV Modules to Module Support Rail assemblies .......................................................... 9
Step 5: Attach Pole Clamp Assembly to Top of Pole .................................................................................. 11
Step 6: Attach Tilt Plate Mounting Channels ............................................................................................. 12
Step 7: Attach Tilt Plates ........................................................................................................................... 13
Step 8: Attach Cross Rails to Tilt Plates ..................................................................................................... 13
Step 9: Attach PV Module Support Rail Sub Assemblies to Cross Rails ...................................................... 14
Step 10: Install Upper Cross Brace and Knee Brace Rails ..... 17
Step 11: Adjust Tilt Angle . 19
Step 12: Install Lower Knee Brace ............. 19
Foundation Hole Guidelines ....................................................................................................................... 24
Installer Responsibility ............................................................................................................................... 26
Warranty Information ............................................................................................................................... 26

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Tools Required
Tools that support the following size hex heads: Torque values are dry, add 15% if using anti seize
lubricant on stainless steel hardware (Recommended). Deep sockets for 5/16 and 1/2, long
combination wrench for 5/16.
1. 1/2 = 480 In Lbs. or 40 Ft Lbs. 2. 3/8 = 240 In Lbs. or 20 Ft Lbs.
3. 5/16= 144 In Lbs. or 12 Ft Lbs. 4. 1/4" = 84 In Lbs. or 7 Ft Lbs.
Components Lists :
LTP LCR/124HW PARTS LIST LTP HLKT 124 HIGH LOAD KIT PARTS LIST
Galvanized coated sheet steel components will show rust on cut edges and is normal
and will not affect the structure and function of the mount.
PART NUMBER DESCRIPTION QTY.
51-07CR-066 REV C Cross Rail, 66 Inch 6
51-07SP-060 REV A Cross Rail Connector 3
51-07TC-068 REV A Panel Support TP 68 inch 4
51-07TC-056 REV A Panel Support TP 56 inch 4
51-07CN-030 REV D Connector, 30" 4
29-UNCP-HLK Under Panel Clamp Kit 3
29-5007-015 Kit, 1/2 x 1.25 (2) Set
Galvanized 1
29-5020-020 Kit, 3/8 x 1 (4 set) Flange 4
29-5020-030 Kit, 3/8 x 1 (6 set) SST 2
29-5002-010 Kit, 5/16 x 7/8 (8 set)
Stainless 4
PART NUMBER DESCRIPTION QTY.
51-07CA-017 6-inch Pipe Clamp Assembly 1
51-07BC-TLT REV A Channel, Tilt Plate Mounting 2
51-07TP-LR2 REV C Tilt Plate L\R 2
51-07CR-066 REV C Cross Rail, 66 Inch 6
51-07SP-060 REV A Cross Rail Connector 3
51-07TC-068 REV A Module Support Rail 68 inch 4
51-07TC-056 REV A Module Support Rail 56 inch 4
51-07CN-030 REV C Connector, 30" 4
51-07KC-066 REV A Upper Cross Rail, 66 inch 2
51-07SP-015 REV A Upper Cross Rail Connector 1
51-0539-HWI rev A Inner Brace Channel 2
51-0539-HWO rev A Outer Brace Channel 2
51-06HW-015 rev A Inner Swivel Bracket 2
51-06HW-020 rev A Outer Swivel Bracket 4
51-07KB-58HW rev A Attaching Angle Bracket 2
51-07KB-59HW rev A Clamp, 6" Knee Brace 1
23-0675-GLV Bolt, U 1/2-13 6" Pipe HDG 1
NOTE: References to physical direction in this manual, such as north and south, apply
to installations in the Northern Hemisphere. For installations in the Southern Hemisphere,
reverse these physical directions.

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LTP LCR/124HW WITH HIGH LOAD KIT HARDWARE BAGS LIST & KIT CONTENTS
BAG PART
NUMBER
PART
NUMBER DESCRIPTION QTY.
29-5007-010 Kit, 1/2 x 1.25 (5) Set
Galvanized 2
Kit Contents
23-5013-125 Bolt, 1/2-13x1.25" HDG 10
25-5002-GLV Washer, Flat 1/2" HDG 20
25-5001-GLV Washer, Lock 1/2"
HDG 5
24-5013-GLV Nut, Hex 1/2-13 Fin
HDG 5
29-5020-050 Kit, 3/8 x 1 (8 set)
Flange 6
Kit Contents
23-3716-100 Bolt, 3/8-16 x 1.0 Hex
SST. 48
25-3702-000 Washer, Flat 3/8" SST. 48
25-2501-016 Nut, Flange Serrated
3/8-16 SST. 48
29-5020-030 Kit, 3/8 x 1 (6 set) SST 2
Kit Contents
23-3716-100 Bolt, 3/8-16 x 1.0 Hex
SST. 12
25-3702-000 Washer, Flat 3/8" SST. 24
25-3701-000 Washer, lock 3/8" SST. 12
24-3716-440 Nut, 3/8-16 Hex SST. 12
29-5002-010 Kit, 5/16 x 7/8 (8 set)
Stainless 5
Kit Contents
23-3118-875 Bolt, 5/16-18 x 7/8 Hex
CS SS 40
25-3102-000 Washer, flat 5/16" SS 40
25-2501-015 Nut, flange 5/16 SST 40
29-5003-000 Kit, 1/4 x 3/4 (8 set)
Stainless 3
Kit Contents
23-2520-050 Bolt, Hex 1/4-20 x .75
SST 24
25-2502-000 Washer, flat 1/4 SS 48
25-2501-000 Washer, lock 1/4" 24
24-2520-440 Nut, 1/4-20 fin hex SS 24
29-5000-010 Kit, 1/4 x 3/4 (4 set)
Stainless 3
Kit Contents
23-2520-050 Bolt, Hex 1/4-20 x .75
SST 12
25-2502-000 Washer, flat 1/4 SS 12
25-2501-014 Nut, Flange Serrated
1/4-20 SST 12
BAG PART
NUMBER
PART
NUMBER DESCRIPTION QTY.
29-5002-200 Kit, Spare Hardware 1
Kit Contents
23-3716-100 Bolt, 3/8-16 x 1.0
Hex SST. 1
25-3702-000 Washer, Flat 3/8"
SST. 2
25-3701-000 Washer, lock 3/8"
SST. 1
24-3716-440 Nut, 3/8-16 Hex SST. 1
25-3102-000 Washer, flat 5/16" SS 1
25-2501-015 Nut, flange 5/16 SST 1
23-3118-875 Bolt, 5/16-18 x 7/8
Hex CS SS 1
23-2520-050 Bolt, Hex 1/4-20 x
.75 SST 1
25-2502-000 Washer, flat 1/4 SS 1
25-2501-000 Washer, lock 1/4" 1
25-2501-014 Nut, Flange
Serrated 1/4-20 SST 1
23-5013-125 Bolt, 1/2-13x1.25"
HDG 1
25-5002-GLV Washer, Flat 1/2"
HDG 1
25-5001-GLV Washer, Lock 1/2"
HDG 1
24-5013-GLV Nut, Hex 1/2-13 Fin
HDG 1

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Pre Assembly for Model LTP LCR/124HW with High Load Kit
Step 1 : Assembling the Aluminum PV Module Support Rails
The kit for the LTP LCR/124HW top of pole mount will contain four 56 and four 68 Module
Support Rails, along with four 30 Connectors. The High Load Kit will contain an additional two
56 and two 68 Rails with two additional 30 Connectors. The two inside rail assemblies are
doubled up to provide more strength for higher wind and snow loading.
A. Start by assembling the two single rail units, one left side and one right side. Lay one 56 and one
68 rail end to end, with the insides of the rails facing the same way, and with the flanges with the
obround slots on the same side of both rails, and bolt them together using one of the 30
Connectors. Center the Connector on the seam between the two rail lengths and be sure that the
obround slots in the Connector are on the same side of the obround slots in the rails.
B. Repeat with a second set of 56 and 68 Module Support Rails and Connector, except reverse the
position of the 56 rail section to be on the opposite end of this 68 Channel compared to the first
assembly. See Detail A for both assemblies.
NOTE: Some parts and hardware come from both the High Load Kit and the basic mount. The
following steps supersede some of the steps in the instruction manual included with the mount
this High Load Kit is being installed onto. The original mount manual should be disregarded, and
this manual used in its place.
NOTE: Each column of three PV modules will need either one left side or one right side single
Module Support Rail assembly (when viewed from the south side of the pole) and one doubled
Module Support Rail assembly. The open sides of the two single rail assemblies (one per column)
will be attached to the back of the PV modules (and then to the mount) facing inward towards the
center of the PV modules. The doubled rail assemblies are to be placed on the inside (nearest to
the pole) of each three module column. All of the rail assemblies need to have the 56 rail
sections on the upper (north end) of each three module column, as shown in Detail E.

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Detail A:
C. Tighten the 5/16 18 x 7/8 hex bolts, flat washers, and flange nuts to 144 in lbs (dry) and set these
assemblies aside.
D. Next, assemble the two double rail units. Each unit will consist of two 56 Module Support Rails,
two 68 Module Support Rails, and two rail Connectors. The two 56 sections need to be together
on the same end of the assembly. Lay two 56 and two 68 Module Support Rails end to end and
back to back with a Connector in the middle on both sides,as shown in Detail B. Make sure that the
side flanges with the obround holes and the side of the Connectors with the obround slots are all
facing in the same direction, and that the two 56 rails are on the same end of the assembly as
shown in Detail B.

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Detail B:
E. Tighten the 5/16 18 x 78 bolts, flat washers, and flange nuts to 144 in lbs (dry) and set these sub
assemblies aside.
Step 2: Assembling the Galvanized Steel Cross Rails
A. To make the two single rail sets, lay two of the 66 Cross Rails end to end, with the rail open sides
facing the same way, and with the sides with the obround slots facing up, with a Connector in the
middle centered on the seam between the two rail sections, with its flange down, as shown in
Detail C. Repeat with the other two pairs of rails and two connectors. Tighten all the 3/8 16 x 1
hex bolts, flat washers, and flange nuts to 20 ft lbs (dry) and set these two sub assemblies aside.
Note: The LTP LCR/124HW Kit will contain six 66 Cross Rails (galvanized steel) and three
Connectors, and the High Load Kit will contain two additional 66 Cross Rails and one additional
Connector. These parts are used to assemble one double rail Cross Rail unit, one single rail Cross
Rail unit, and one single rail Knee Brace Cross Rail unit.

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Detail C:
B. To make the double rail assembly, lay four of the Cross Rails end to end and back to back, as shown
in Detail D. Make sure that the sides with the obround slots all face up. Place two rail connectors, one
on each side, in the open sides of the rails, centered on the seam between the two rail halves, and
with their flanges down, as shown in Detail D. Bolt the double rail assembly together using the 3/8
16 x 1 hex bolts, flat washers, and flange nuts. Tighten all the bolts to 20 ft lbs (dry) and set this
assembly aside.
Detail D:

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Detail D complete:
Step 3: Assembling the Aluminum Upper Cross Rail
There are two 66 aluminum Upper Cross Rails included, used with the supplied aluminum
Connector to assemble one 132 Upper Cross Rail assembly.
A. Lay the two 66 Upper Cross Rails end to end, with the obround slots facing up, the open sides
facing the same direction. Place the Connector inside the rails, centered over the seam between the
two rail sections, and with the connectors flange down, as shown in Detail E. Bolt the assembly
together using the supplied 5/16 18 x 7/8 hex bolts, flat washers, and flange nuts. Tighten to 144
in lbs (dry). Set this sub assembly aside.
Detail E:

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Step 4: Connecting PV modules to Module Support Rail assemblies:
The LTP LCR/124HW mount, with the added High load Kit, utilizes three PV modules per column,
two columns side by side. For assembly purposes, attach the middle PV modules only at this point,
one to each pair of Module Support Rails, as shown in Detail F. This will establish the spacing
between the Module Support Rails based on the mounting hole locations in the PV module
frames, which vary by brand and model.
You will need to make one left side and one right side sub assembly (left and right determined by
viewing from the south side of the pole). The doubled Module Support Rail assemblies will need
to be located to the inside (pole side) in both columns and the 56 module support rail sections
need to be on the north side of the pole as shown in Detail F. Be sure to place the PV modules on
the rails with their wiring junction boxes on the proper side based on the wiring note above.
NOTE: For ease of wiring and wire management of the PV modules, it is best to have as much of
the output wiring as close to the inside, near the pole. PV module brands and models can differ
in the location of their output wiring junction boxes. Additionally, the proper location of the
junction boxes on the mount may differ depending on whether the modules are to be wired in
series or parallel, or a combination of series and parallel. This depends on the intended use for
the solar array. Be sure to plan this out beforehand.
If the PV modules that you are using have a single wiring junction box (containing wiring for
both positive and negative connections to it) at one end of the back of the modules, it is best if
all of the modules are mounted on the racking with these junction boxes towards the inside
(closest to the pole), in each of the two module columns. Since during later assembly of the two
columns of modules to the Cross Rails, the 56 sections of the Module Support Rail assemblies
need to be on the north side of the pole (higher side when tilted), make sure that while
assembling (per the following instructions) that you attach the center PV module to one pair of
Module Support Rail assemblies with the modules junction box on one side of the rails, and
assemble the second set with the center modules junction box on the other side of the rails, in
relation to the 56 rail sections of each Module Support Rail sub assembly.
If the PV modules have two wiring junction boxes in the middle of the module (one positive and
one negative), the best arrangement for wiring will vary depending on usage. Be sure to plan
out your wiring options before attaching the modules to the Module Support Rails. If the
modules are to be wired in series strings, make sure that the wire leads are long enough to
reach between modules

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A. Lay one of the PV modules on a flat surface, frame side up as shown in Detail F
B. Place one doubled and one single Module Support Rail assembly across the PV module with
the obround slots in the rails face down on the module frame, and the open side of the single
rail assembly facing towards the center of the module, as shown in Detail F . Make sure that
the 56 sections of the rail assemblies are on the same side of the PV module (also see note
on previous page about placement of the PV module wiring junction boxes). Place the PV
module in the center of the rail assembly and align the mounting holes of the module frame
with the obround slots on the Module Support Rails. Attach the rail assemblies to the module
frame using the 1/4" x 3/4" bolts, flat washers, lock washers and nuts. Tighten only enough to
hold firmly,
do not fully torque at this time .
C. Repeat Step 4 A and B with a second PV module, the second double rail assembly and the
second single rail assembly. However, you may want to have the PV modules junction box on
the opposite side of the rail assemblies, or with a different polarity position on the rails, per the
note about junction boxes above. Make sure that the 56 sections of the rail assemblies are on
the same side of the PV module. Tighten only enough to hold firmly,
do not fully torque at this
time . Set aside these two PV module and rail sub assemblies.
Detail F:
Note: On the doubled Module Support Rail assembly, the assembly is only bolted to the module
frame, using the mounting holes in the PV modules frame, on the inside of the rail assembly  the
side facing the center of the PV module. The outer doubled Module Support Rail in the assembly
will be attached later.

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Step 5: Attach Pole Clamp assembly to Top of Pole
A. Loosen the four 1/4" bolts on the top of the Pole Clamp slightly to allow enough slack for the Clamp
halves to slip over the top of the pole and slide the pre assembled Pole Clamp unit over the pole.
The top edges of the pole should fit into the notches of the Pole Clamp assembly (see Detail G).
B. Orient the long side of the pole clamp to face in the desired solar array direction. This is generally
true South, although site specifics may dictate a different array orientation.
C. Tighten the 8 outside 5/16 flange nuts on the threaded rods evenly, making sure that each nut is
tightened the same amount of turns so the distance between the Clamp halves is the same on each
side of the pole, until the torque setting is reached. 12 Ft lbs (dry).
D. Finger tighten the 8 inside 5/16 flange nuts on the threaded rods up to the flanges of the Clamp
halves. Using a long 5/16 box wrench, tighten the 5/16 inside flange nuts, alternating turns from
side to side, pulling the flanges closer together. (Close to or touching each other, but not flattened
out). This tightens the two sides of the clamp to the outside of the pole.
E. Install the four 5/16 x 7/8 bolts, each with a flat washer against the heads, and flange nuts in the
four holes of the clamp halves flange ends. Tighten the 5/16 bolts, alternating turns from side to
side, pulling the outer flanges together (again, close or touching, not flattened out) (see Detail G).
F. Check the torque of the 8 outside flange nuts, and re torque as needed.
G. Torque the four previously loosened 1/4" bolts on the top of the Pole Clamp to 84 in lbs.
H. (Optional) caulk the seams on top of pipe clamp to seal, to prevent water from entering the
pipe.
Detail G: Detail H:

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Step 6: Attach Tilt Plate Mounting Channels
A. Place the two Tilt Plate Mounting Channels on the sides of the Pole Clamp assembly as shown in
Detail I. Also note the helpful tip in Detail I.
B. Install 1/4" bolts, flat washers, and flange nuts in the six mounting holes on each Tilt Plate
Mounting Channel (two on each side, and two on the top). Tighten to 84 in lbs.
Detail I:
Note: Placing the flange nut in the closed side of the wrench to align with the bolt through
the cutout will make it easier to start the nuts on the treads and help prevent dropping the nut
into the assembly where they cannot be easily retrieved. (see photo in Detail I).
Helpful tip:
Pre install 1/2 bolt in these
holes on both channels for
ease of assembly in Step 7

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Step 7: Attach Tilt Plates
A. Attach Tilt Plates, with the flanges facing to the outside as shown in Detail J, using the six 1/2 13 x
1.25 bolts (three for each Tilt Plate), flat washers, lock washers and nuts. Position the Tilt Plates
with the top level (0° tilt). Do not torque at this point, but tighten snuggly, only enough to hold the
Tilt Plates firmly for the next assembly steps.
Detail J:
Step 8: Attach Cross Rails to Tilt Plates.
A. Place the previously assembled doubled Cross Rail assembly across the north end of the Tilt Plates,
and one of the single rail Cross Rail assemblies across the south end of the Tilt Plates, with the open
side of the single rail assembly facing to the inside. Place so that both rail assemblies have the
obround slots facing up, as shown in Detail K. Center the two assemblies on the Pole Clamp, using
the seam between the two Cross Rail sections as the location of the center of the assembly. Attach
the two Cross Rail assemblies to the Tilt Plates using the 1/2" 13 x 1.25 bolts, flat washers, lock
washers, and nuts, in the six places shown in Detail K. Torque to 40 ft lbs.

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Detail K:
Step 9:Attach PV Module Support Rail Sub Assemblies to Cross Rails
A. Lean one of the 124 module support sub assemblies (with the single center PV module attached)
against the cross rail, as seen in Detail L, with the 56 Rail sections on the north end, the doubled
rail assembly to the inside (near the pole) and with the PV modules wiring junction box in the
proper location for final wiring. Lift the bottom end up and slide the sub assembly onto both Cross
Rails.
Note: Make sure that the 56 sections of Module Support Channels are on the north end of the
two Cross Rails, and that the doubled Module Support Rail assembly is toward the inside near
the pole. Make sure that the PV module wiring junction box is in the proper location for wiring. If
all three of those directives are not present, either the assembly was not done correctly, or this
particular assembly needs to go on the other side of the pole.

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Detail L:
B. Place the seam, where the 56 and 68 Module Support Rails meet, centered between the two
Cross Rail assemblies.
C. Place the inside edge of the PV module near the center of the Cross Rails (where the seam is
between the two connected Cross Rails). See Detail M. Move in or out to leave 1/2 of the desired
spacing between the two PV module columns (east to west). Spacing between the two columns is
typically around 1 but can be wider if there is enough space on the Cross Rails to catch the full
assembly (a wider gap will let more wind pressure through).
Detail M:

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D. Drop eight 3/8 x 1 bolts with flat washers into the appropriate slots in order to bolt the Module
Support Rails down to the Cross Rails as shown in Detail N. There will be three bolts on each side of
the doubled Module Support Rail. Add the bottom flat washers, lock washers and nuts, finger tight.
Check the center gap spacing and adjust if necessary. Make sure that the Module Support Rails are
square to the Cross Rails, and torque the 3/8 x 1 bolts to 20 ft lbs.
Detail N:
E. Repeat A through D above for the second Module Support Rail/PV module assembly on the other
side of the pole, again making sure that the doubled Module Support Rail is towards the inside, that
the 56 sections of the support rails are on the north end, and that the PV modules junction box is in
the proper location.
F. Lift the next PV module (#3 of the six) up onto one of the Module Support Rail assemblies on the
north side (again with the modules junction box in the proper location). Align the mounting holes so
that the gap between it and the center module is approximately 1. Loosely install with 1/4" x 3/4"
bolts, flat washers, lock washers and nuts. Repeat with the fourth module on the other side of the
pole, north end, then repeat again with the remaining two PV modules on the south sides of the two
columns. All module wiring junction boxes should be checked for proper location.
G. Do a final adjustment of all of the spacing of all the PV modules to be even and parallel, and torque
the 1/4 bolts to 84 in lbs.

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H. Install the under module clamps to the outer rail of the doubled Module Support Rails as shown in
Detail O.
Detail O: (viewed from underside)
Step 10: Install Upper Cross Brace and Knee Brace Rails
A. Install Upper Cross Brace Rail assembly, with the open side facing the pole, across the north
underside of the Module Support Rail assemblies. Place the 5/16 18 x 7/8 bolts, flat washers and
flange nuts in the last hole in from the end of the Module Support Rails, as shown in Detail P The
ends of the Upper Cross Brace Rail should be the same distance in from the ends as the two main
Cross Rails are to the Module Support Channels. Torque to 144 in lbs (dry).
Detail P:

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B. Repeat across the south end of the Module Support Rails, using the third set of Cross Rails
previously pre assembled (see Details Q and R). This will act as the Knee Brace Cross Rail. Install
with the open side of the Rail assembly facing the pole, and the same distance in from the ends as
the other Cross Rails.
Detail Q:
Detail R:
Note: the location of this Knee Brace Cross Rail assembly is determined by the final desired angle
setting for the array, as seen in the table in Detail Q.

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Step 11: Adjust Tilt Angle
A. Remove the lower two 1/2" 13 x 1.25 bolts from the Tilt Plates and tilt the array to the desired
angle. The array tilts in 10° increments from 0° to 60°. Re install the 1/2" 13 bolts and torque all six
bolts (three per Tilt Plate) to 40 ft lbs.
Step 12: Install Lower Knee Brace
A. Pre assemble the Lower Knee Brace Clamp body to the Angle Brackets with the 1/4x 3/4 bolts, flat
washers and flange nuts, and torque to 84 in lbs. (see Detail S). Set aside the 5/16 18 x 1 bolt, flat
washer and flange nut attached to one of the Angle Brackets.
Detail S:
B. Attach the Lower Knee Brace Clamp loosely to the pole with the 1/2" 13 x 6" U bolt, flat washers,
lock washers and nuts as shown in Detail T). Hand tighten just enough to keep it from sliding down
the pole. See previous Detail Q table for clamp location position on the pole.
Detail T: