TerraGen TGR User manual

Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
Installation Manual
TerraGen Environmental Group
120 Parson Rd.
Alliston, Ontario, L9R 1E9
705-435-7373
Version: 30/04/2021

TGR System 1
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
Table of Contents
1. General................................................................................................................................. 2
2. Material Receiving ............................................................................................................... 2
3. Tools Required ..................................................................................................................... 3
4. System Components ............................................................................................................ 4
5. Annual Maintenance Activities............................................................................................ 5
6. Installation of System .......................................................................................................... 6
6.1 Prep Work & Pre-assembly.................................................................................................. 6
6.1.1 Tilt Assembly Installation.............................................................................................. 6
6.1.2 Cutting Rails.................................................................................................................. 6
6.2 Base Rail Installation ............................................................................................................ 6
6.2.1 Base Rail Layout............................................................................................................ 6
6.2.2 Rubber Pad Installation ................................................................................................ 7
6.2.3 Base Rail Splicing .......................................................................................................... 9
6.3 Top Rail Installation ............................................................................................................. 9
6.3.1 Cross Adapter Setup ..................................................................................................... 9
6.3.2 Top Rail Layout ........................................................................................................... 11
6.3.3 Top Rail Splicing.......................................................................................................... 12
6.3.4 Top Rail Thermal Breaks ............................................................................................. 12
6.4 Ballast Installation.............................................................................................................. 13
6.5 Home Run Wiring............................................................................................................... 13
6.6 Module Installation............................................................................................................ 14
Appendix A: Ballast Requirements ............................................................................................... 15
Appendix B: Bonding & Grounding............................................................................................... 16
Appendix C: Installation Efficiencies............................................................................................. 17
Appendix D: Wire Management Options ..................................................................................... 18
Appendix E: MLPE Mounting ........................................................................................................ 19
Appendix F: UL 2703 Fire Classification ........................................................................................ 20

TGR System 2
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
1. General
The TGR System is designed to be installed on a flat or low sloping roof for an array of
any size, provided the guidelines within this manual and any other applicable codes and
standards are followed. It is a rail-based design intended to secure 2-8 modules per rail,
with continuity through splicing to create a grid-system. The system can be installed in
landscape or portrait orientation for PV modules up to 45” X 90”, provided the project
specific design has been done accordingly and the module manufacturer guidelines are
followed. To ensure proper installation and prevent a void of your warranty, the
installation manual and the project specific documentation must be followed. In unique
or custom cases where alternative components or design is required, the project
specific documentation will supersede the installation manual where there is insufficient
or conflicting information.
2. Material Receiving
A detailed bill of lading will be sent with the shipment of racking. The receiver must
confirm that all parts received are according to the detailed Bill of Lading and Packing
Slip. Any damage must be noted on the bill of lading upon receipt. Any discrepancies
must be reported within 2 business days. Otherwise, all claims will be invalid. If there
are any damaged parts or rails, please provide a picture as well as documenting it on the
Bill of Lading.

TGR System 3
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
3. Tools Required
5/16 socket (for Tek screw), 13mm
deep socket (for 8mm nut)
+
13mm Open-Ended / Combo Wrench
5mm Metric Allen Key OR 5mm Allen
Key Socket
or
Socket wrench with matching drive
for each of the above
(i.e. 3/8 or 1/2" drive)
OR Cordless drill and socket adapter
for each of the above
or +
Chalk line and measuring tape
+
7 ft-lb and 12 ft-lb
pre-set slip type torque wrenches OR
an adjustable torque wrench
or
Miscellaneous
•Onsite cutting ability
•Cold galvanizing spray
-Use of impact tools when installing clamps and hardware will cause galling (seizing of SS hardware). TerraGen
will not free issue components damaged from use of impact tools.
-All fasteners must be torque marked after applying the required torque.

TGR System 4
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
4. System Components

TGR System 5
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
5. Annual Maintenance Activities
The activities described below for the maintenance of the solar racking provided by
TerraGen must be performed a minimum of every 12 months from the date of
installation up until the system has been decommissioned. Records with images of the
inspection must be recorded and kept.
•Perform a visual inspection of the system to check all components for any signs of
defect. Any components showing signs of damage that compromise safety shall be
replaced immediately.
oCheck for any deformation, penetrating corrosion, or other noticeable
defects in the components.
oInspect roofing condition around the contact points with the roof and that
the system has not moved over time. Ensure appropriate roof protection is
still secured appropriately in place.
oBallast (when applicable) is secured as intended with no cracks or
degradation.
oModules are seated correctly and secured.
•Check all hardware for specified torque or torque marks. Any loose components or
fasteners shall be re-tightened in accordance with the installation instructions.

TGR System 6
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
6. Installation of System
6.1 Prep Work & Pre-assembly
6.1.1 Tilt Assembly Installation
Assemble the tilt assemblies onto the base rails using the M8 - 50 mm bolt through the
pre-drilled holes and securing with the M8 serrated nut. Start with installing one tilt
assembly at the North and South of every base rail that has been laid out. Each bolt shall
be torqued to 7 ft-lbs.
A is where tilt assemblies are placed. B is space between tilt assemblies. S + N = B in
most cases. N and S represent the amount of base rail left over at the North end and
South end, respectively.
Base Rail Side View
6.1.2 Cutting Rails
Please refer to the Construction Package for the cuts required for the project, it is
advantageous to set up a cutting station to prep all of these before installation.
6.2 Base Rail Installation
6.2.1 Base Rail Layout
Locate the starting point for the first base rail according to the Construction Package.
The remainder of the base rails can be located in reference to the starting base rail with
M8 x 50 Hex Bolt
M8 Serrated nut
NOTE: Torque to 7 ft-lbs.
Torque the pre-assembled nut to 7
ft-lbs.

TGR System 7
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
Base Rail Starting Layout Plan View
proper center to center spacing from the Construction Package, by measuring or using a
spacing jig. No additional measurements are absolutely required to align the front and
back base rails, though a string or laser line can be helpful.
6.2.2 Rubber Pad Installation
A rubber pad is used to protect the roof membrane. Place the rubber pad underneath
the base rails before the placement of rails. Typical rubber pad supply is a recycled
rubber under the base rails that is not attached to the system. TPV Rubber pad can be
requested as a substitute, for which see below for installation instructions.
Base Rail Starting Layout Plan View
Note: Refer to the Construction Package
for X, Y, b, and d dimensions.
Starting point N-S
Rubber Pad
Base Rail

TGR System 8
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
TPV Rubber Pad Installation (Only applicable to TPV Rubber Substitution)
TPV Rubber pad is to be slid onto the flanges of the base rails following the rubber
coverage requirement from the Construction Package. To ensure the rubber slides on
properly, the tilt assemblies must be installed first, and the rail should be flipped upside
down for ease of sliding. Best practice is to use a sawhorse for the tilt assemblies & the
rubber pads as the first step of the installation.
Typical coverage is 30” pcs of the TPV Pad spaced 12” apart.
1) Flip Base
Rail over
2) Slide Rubber
on to Base Rail
Roof warranty holder should be contacted to ensure compatibility with the roof membrane and ensure the roof warranty
is maintained, if applicable.
Typical coverage is 30" pcs of the rubber pad spaced 30" apart. If any part of the base rail is contacting the roof in
locations without the rubber pad, shift the rubber pad accordingly to protect contact points ensuring that a minimum of
3" has been left for drainage.
Ensure that all edges of the base rail are protected by the rubber pad.
Alternative rubber coverage can be accommodated at customer's request.

TGR System 9
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
6.2.3 Base Rail Splicing
To connect adjacent base rails, 12 TEK screws (4 per side) are to be used to fasten the
base rail splice over the 2 base rails.
Roof Slope Changes
Splices can accommodate minor changes in roof slope changes as shown below.
6.3 Top Rail Installation
6.3.1 Cross Adapter Setup
Use cross adapters to secure the top rails to the tilt assemblies. Click the cross adapter
onto the tilt assembly to attach a top rail. Unless otherwise specified on the
Clean all metal shavings created from the provided metal screws and spray the assembly with a Cold
Galvanizing Compound.
If roof slopes cause a drastic peak or valley that cannot be accommodated utilizing rubber shims or
alternative and is causing an S-bend in the base rail, then the array may need to be cut and spliced back
together referring to the images below.

TGR System 10
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
Construction package, 2 cross adapters per connection are only required on the edge of
the base rails while all other connections in the field will require just 1 cross adapter.
Refer to the diagram below to further describe the configuration pattern and the
alternating sequence between inside and outside configurations in the field.
Use the pattern shown (below, right) to attach cross adapters on both sides of each rail
for farthest east and farthest west columns. All other interior columns receive cross
adapters on the insides of top rails, or outsides of top rails, in alternating sequence.
Cross
Adapters
Find this distance “d” in the
Construction Package.
(B) Cross Adapters on insides of top rails
(A) Cross Adapters on both sides of each top rail
(C) Cross Adapters on outsides of top rails
(C)
(A)
(A)
(C)
(B)
(B)
(B)
Pattern for Cross Adapters when
there are more than 3 base rails
North
1) Clip
one side
2) Click on to
other side

TGR System 11
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
Top Rail Starting Layout Plan
6.3.2 Top Rail Layout
Top rails should be installed in the locations specified by the top rail layout plan. The
layout plan can be found in the Construction Package. Please refer to it for top rail cut
lengths and positions.
The maximum overhang amount is also specified in the construction package and it is
measured from the edge of the mounted panel to the base rail. A minimum of 2” of top
rail is required past the end of the module on the starting side.
Panel Overhang (Refer to Const. Pkg)
Top Rail past end of module on starting
side

TGR System 12
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
6.3.3 Top Rail Splicing
When required, the top rails get spliced together with a bonding integrated splice bar.
Ensure that the top rail is stopped by screw head and that the bonding clip is engaged
with the aluminum from both rails. Where thermal breaks are required, a ¾” gap must
be maintained between the ends of the top rails.
6.3.4 Top Rail Thermal Breaks
In the case of extended rows, where a thermal break is required (refer to Construction
Package), a module break is required divided by two end-clamps and a splice.
Top Rail Splice
Top Rail
Top rail
Integrated
Bonding Clip
Top rail splice
End clamp
Solar module
¾” Gap
Due to undulations on the roof surface, the angle between the thermal break and the rails may be too large
(>2 deg) to allow sliding of the rails on the splice. If this occurs, then the splices on either side of the rail which
are not thermal breaks should be Tek screwed to lock them in place.
Screw Head

TGR System 13
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6.4 Ballast Installation
Secure blocks with the provided ballast clamp in the appropriate locations according to
the ballast plan on the Construction package. Please refer to the ballast block drawing
for further information located in the Construction Package.
TGR Assembly with Ballast
Ballast Tray Alternative
If ballast trays are required utilize the configurations below corresponding to the ballast
plan of the Construction package.
6.5 Home Run Wiring
After top rail installation is complete, this would be the best time to run all PV cable and
home runs as this allows the installer to have free range of access to the racking for
securing the PV cable.
1
2
3
4
5
6
7
8
TGR Assembly with 6 Block Ballast Tray
TGR Assembly with 4 Block Ballast Tray
1
3
5
2
4
6
1
2
3
4

TGR System 14
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
6.6 Module Installation
Install the modules by first clicking the end clamps onto the end of the top rails. Adjust
the module to the proper position and tighten the end clamps to 7 ft-lbs. Next, click the
mid clamps and bonding washer onto the top rail (refer to Appendix B).
Slide the mid-clamp in tight to the module making sure that the tab of the bonding
washer is placed under the module frame. Once the next module is placed properly, the
mid clamp can then be secured and torqued to 12 ft-lbs.
WEEB CCR2 (Upon Request)
End clamp
Mid-clamp w/ Bonding washer
End-Clamp
Mid-
Clamp
Bonding
Washer
Min. 2”
(See Note)
Top Rail
In the circumstance where the modules being installed have 50mm frames, care needs to be taken when
installing mid clamps and end clamps as the bolt will be on its last few threads. Hand loosen the bolt prior to
installing on rail.
See construction package for details on clamp zones. TerraGen makes every attempt to ensure that the module clamping
zones of the module manufacturer are met. However, ultimately it is the responsibility of the customer to verify that the
module warranty will be maintained.

TGR System 15
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
Appendix A: Ballast Requirements
The TGR Ballasted System has been designed utilizing concrete blocks that range from 30-33
lbs. Provided components are designed to these dimensions, and any discrepancy with the
block size will alter the function of these components. While these standard sizes are
recommended for use with the TGR system, custom sizes can be accommodated upon review
and approval by TerraGen. Refer to the project specific construction package for ballast weight,
quantity, and placement.
Notes:
1. RANGE OF DIMENSIONS (D x H x W): 15 3/8” x 7 1/2” x 3 1/2” to 15
9/16” x 7 1/2” x 3 5/8”
2. ALLOWABLE WEIGHT VARIANCE: ± 0.32 kg (0.71 lbs)
3. Dimensions may slightly vary depending on location of blocks
Mechanical Attachments
An alternative method of uplift/lateral resistance is the use of roof attachments. TerraGen’s
system is compatible with various attachment options. One example of an attachment is shown
below. Refer to the project specific construction package for details if attachments are
required.

TGR System 16
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
Appendix B: Bonding & Grounding
The system has been evaluated/certified for Grounding/Bonding, and conforms to UL 2703.
Refer to ‘Module Listings’ document for modules that have been certified to LTR AE-001-2012
and UL 2703.
Connection 1: Module to Top Rail
Mid-clamps with bonding washers bond rails to module frames with teeth
piercing the anodized surface of the module.
Connection 2: Top Rail to Top Rail
In cases where two or more rails may need to be spliced together, top
rails are spliced through a sliding splice which consists of a bonding
clip that pierces the surface of the aluminum rails.
Connection 3: Top Rail to Tilt Assembly
Top rails are connected to tilt assemblies using cross adapters.
Connection 4: Tilt Assembly to Base Rail
Tilt assemblies connect onto the base rails using the M8 - 50 mm bolt
through the pre-drilled holes and secured with the M8 serrated nut.
Connection 5: Base Rail to Base Rail
12 TEK screws (4 per side) fasten the base rail splice over 2 flush base
rails.
Connection 6: Grounding Each Array
Ilsco SGB-4 or other UL 467 listed Grounding Device (supplied by others) is used to ground the
system. Provided the previously mentioned connections all apply; each individual array only
needs to be grounded once (though 2 locations are suggested). Location for grounding device is
often the back leg of the tilt assemblies or the excess end of a top rail.
1) Clip
one
side
2) Click on
to other
side

TGR System 17
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
Appendix C: Installation Efficiencies
Pre-Assembly of Tilt Assemblies on Base Rails
If a holding rack is available, such as the one shown in the photo below, you may choose to use
this method to speed up the assembly process.
Prior to hoisting the skid of tilt
assemblies and the bundle of
bottom rails to the roof of
your building, take time to
pre-assemble the tilt
assemblies onto the bottom
rail while still on the ground.
Using sawhorses to hold the
work piece at waist height, cut
all necessary lengths. Refer to
your Construction Package for
lengths of base rails.
Once cut, place tilt
assemblies onto the entire
length, lining them up to
the holes. Use the M8 bolt
and serrated nut to fasten
the tilt assembly in place.
Torque to 7 ft-lbs. Place on
holding rack. Ensure that
the bundle is adequately
secured to the holding rack
for hoisting to the roof.
Telescopic Handler hoisting a holding rack with assembled base rails.

TGR System 18
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
Appendix D: Wire Management Options
PHOTO #1: East West rails can be used to secure PV
wire. In this image, the installer has used PVC straps
secure on the rail to support the PV wire.
PHOTO #2: Another option for securing the PV wire to
the east west rails is the optional wire management
clips that TerraGen offers.
PHOTO #3: PV wire management using the optional
wire management clips on the solar panel.
PHOTO #4: TGR base rails, (the north south rails) can be
used to secure wires requiring management from row to
row. We permit installers to secure wire management
components to our base rail. In this case the installer used
PVC conduit.
PHOTO #5: Row to row DC wiring can be pulled
through PVC conduit attached to the base rail and split
loom wire protection.
PHOTO #6: TGR base rails can be used to
support cable tray for wire support running from
West to East.

TGR System 19
Tel: [phone] | www.terragensolar.ca | [email protected] | 120 Parsons Rd, Alliston, ON L9R 1E9
Appendix E: MLPE Mounting
T-Bolt assembly is available upon request from TerraGen to mount MLPE (microinverter or
optimizer) into the channel of TerraGen rails. Ensure that guidelines from the MLPE installation
manual are followed.