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

LTP HW Mount Series
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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.