Tamarack Solar LTP HW Mount Series User manual

LTP HW Mount Series
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.
Installation
Manual
LTP LCR/82HW HLK M v2.1
For Model:
LTP LCR/82HW Top of Pole Mount
With added High Load 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/82HW pole-top mount kit. When installing the
LTP-LCR/82HW 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 Top of Pole Mount is an extremely sturdy, universal pole mounting solution for small area solar
photovoltaic (PV) needs. 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
customer support at 1 800 819 7236 ext. 556 or email us at s[email protected]
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 ....................................................................... 5
Step 3: Pre Assembling the Aluminum Upper Cross Rail ...................................................................... 7
Step 4: Connecting PV Modules to Module Support Rail assemblies .................................................... 8
Step 5: Attach Pole Clamp Assembly to Top of Pole ............................................................................ 9
Step 6: Attach Tilt Plate Mounting Channels ....................................................................................... 11
Step 7: Attach Tilt Plates ..................................................................................................................... 12
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 ...... 16
Step 11: Adjust Tilt Angle .. 18
Step 12: Install Lower Knee Brace ....... 18
Foundation Hole Guidelines ................................................................................................................. 23
Installer Responsibility ........................................................................................................................ 25
Warranty Information ........................................................................................................................ 25

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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.
T ools Required:
Tools that support the following size hex heads: Torque values are dry, add 15% if using anti
seize lubricant on stainless 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.
2. 5/16= 144 In Lbs. or 12 Ft Lbs. 3. 1/4" = 84 In Lbs. or 7 Ft Lbs.
Components List :
The following parts are used on the LTP LCR/82HW mount model with added High Load Kit:
LTP LCR/82HW PARTS LIST LTP HLKT 82 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
51-04TC-082 Rev D Module Support Rail, 82 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
51-04TC-082 Rev D Module Support Rail, 82 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
51-0534-HWI rev A Inner Brace Channel 2
51-0534-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 Bracket 2
51-07KB-59HW rev A Clamp, 6" Knee Brace 1
23-0675-GLV Bolt, U 1/2-13 6" Pipe HDG 1

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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
29-5020-040 Kit, 3/8 x 1 (4 set) SST 3
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 3
Kit Contents
23-3118-875 Bolt, 5/16-18 x 7/8
Hex CS SS 24
25-3102-000 Washer, flat 5/16" SS 24
25-2501-015 Nut, flange 5/16 SST 24
29-5003-000 Kit, 1/4 x 3/4 (8 set)
Stainless 2
Kit Contents
23-2520-050 Bolt, Hex 1/4-20 x .75
SST 16
25-2502-000 Washer, flat 1/4 SS 32
25-2501-000 Washer, lock 1/4" 16
24-2520-440 Nut, 1/4-20 fin hex SS 16
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/82HW with High Load Kit
Step 1: Assembling Doubled Aluminum Module Support Rails
The kit for the LTP LCR/82HW top of pole mount will contain four 82 Module Support Rails,
and the LPT HLKT 082 High Load Kit will contain an additional two 82 Rails. The two inside rail
assemblies are doubled up to provide more strength for higher wind and snow loading.
A. Lay two of the 82 Module Support Rails back to back, as shown in Detail A. Bolt together using the
5/16 18 x 7/8 hex bolts, flat washers and flange nuts. Tighten to 144 in lbs (dry).
B. Repeat with a second set of two 82 rails to complete both doubled rail assemblies and set these
two assemblies aside.
Detail A:
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 two PV modules will need one single Module Support Rail 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 two module column.

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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 between on the seam between the two rail sections, with its flange down, as
shown in Detail B. 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.
Detail B:
Note: The LTP LCR/82HW 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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B. To make the double rail assembly, lay four of the Cross Rails end to end and back to back, as shown
in Detail C. 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 C. 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 C:
Detail C complete:

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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 D. 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 D:

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Step 4: Connecting PV modules to Module Support Rail assemblies:
The LTP LCR/82HW mount utilizes two PV modules per column, two columns side by side. For
assembly, attach the two PV modules to each pair of 82 aluminum Module Support Rails, as
shown in Detail E. 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. 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.
A. Lay two of the PV modules on a flat surface, frame side up as shown in Detail E.
Detail E:
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.
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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B. Place one single Module Support Rail and one doubled Module Support Rail assembly across
the PV modules with the obround slots in the rails face down on the module frames, and the
open side of the single rail facing towards the center of the modules, as shown in
Detail E . If
the PV modules have a single wiring junction box on the back, place the doubled rail
assembly near the end of the module where the junction box is as shown in Detail E (or see
note on previous page) if the modules have two central junction boxes). Align the mounting
holes of the modules with the obround slots on the rails, leaving a space between them. Typically,
a 1 spacing is used, but if the modules are wider than 40.5, this space may need to be smaller.
Conversely, if the modules are narrower, this space can be wider. Attach the rails to the module
frames using the 1/4" x 3/4 bolts, flat washers, lock washers and nuts, tighten only enough to hold
firmly, do not fully tighten at this time.
C. Repeat Step 4 A and B with a second pair of PV modules, the second double rail assembly and
the second single rail. Tighten only enough to hold firmly, do not fully torque at this time .
Set aside these two PV module and rail sub assemblies.
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 as shown in
Detail F.
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 will tighten the two sides of the clamp assembly to the outside of the pole.
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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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 F: Detail G:

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Helpful tip: Pre install 1/2"
bolt in these holes on both
channels for ease of assembly
later in Detail H.
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 H. Also note the helpful tip in Detail H.
B. Install 1/4" bolts, flat washers, and flange nuts in the six mounting holes on each Tilt Plate
Mounting Channel
Detail H:
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 F).

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Step 7: Attach Tilt Plates
A. Attach Tilt Plates, with the flanges facing to the outside as shown in Detail I, 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 I:

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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 J. 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 J. Torque to 40 ft lbs.
Detail J:

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Step 9:Attach PV Module Support Rail Sub Assemblies to Cross Rails
A. Lean one of the 82 module support sub assemblies (with the two PV modules attached) against
the cross rail, as seen in Detail K, with 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.
Detail K:
B. Place the rail and module assembly 22 7/8 out from the north side of the north Cross Rail, as
shown in Detail L.
Detail L
Note: Make sure that the doubled Module Support Rail assembly is toward the inside near the
pole. Make sure that the PV module wiring junction boxes are in the proper location for wiring. If
these 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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C. Place the inside edges of the PV modules near the center of the Cross Rails (where the seam is
between the two connected Cross Rail sections), as shown in Detail M. Move in or out for 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:
D. Drop the four 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. 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

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E. Repeat Step 9 A through D with the other PV module and Module Support Rail assembly on the
other side of the pole. Make sure that this columns PV module junction boxes are in the proper
location.
F. 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 holding all of the PV modules to the Module Support Rails to 84 in lbs.
Step 10: Install Upper Cross Brace and Knee Brace Rails
A. Install the previously assembled 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 O. 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 Rails. Torque to 144 in lbs (dry).
Detail O:

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ANGLE A B C
0° 19.06 6.50 31.52
10° 19.06 6.50 36.45
20° 15.06 6.50 40.94
30° 5.06 6.50 46.09
40° 3.06 8.50 51.65
50° 1.06 16.50 43.58
60° 1.06 20.50 42.10
Location Chart LTP LCR/82HW
B. Repeat across the south end of the Module Support Channels, using the third set of Cross Rails
previously pre assembled, as shown in DETAILS P and Q. This will act as the Knee Brace Cross Rail.
Install with the open side of the Rail assembly is facing the pole.
Detail P:
Detail Q:
Note: the location of this Knee Brace Cross Rail assembly is determined by the final desired angle
setting for the array. See the table in DETAIL N ).

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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 R). Set aside the 5/16 18 x 1
bolt, flat washer and flange nut attached to one of the Angle Brackets.
Detail R:
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 S). Hand tighten just enough to keep it from sliding down
the pole. See previous Detail P table for clamp location position on the pole.
Detail S:

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C. Loosely attach the Outer Swivel Brackets to the Lower Knee Brace Clamp with the (previously set
aside) 5/16 18 x 1 bolt, flat washer, and flange nut, as shown in Detail T.
Detail T:
D. Attach the two Outer Swivel Brackets to the lower flange of the Knee Brace Cross Rail, one on each
side, and 21 in from the ends of the Knee Brace Cross Rail, as shown in Detail U. using the 5/16
18 x 7/8 bolts, flat washers, and flange nuts (two bolts per bracket). Flange nuts to be on the
inside of the Knee Brace Cross Rail. Tighten to 144 in lbs (dry).
E. Loosely attach the Inner Swivel Brackets to the Outer Swivel Brackets, as shown in Detail U, using
the 5/16 18 X 3.5 bolts, flat washers, and flange nuts.
Detail U:
Note: The flanges on both brackets need to face to the outside as shown in Detail U.