U.S. Solar Mounts 30 Series User manual

1
U.S. Solar Mounts
TOP OF POLE MOUNTS
30 & 40 SERIES INSTALLATION MANUAL
Models: 3160, 3260, 4160, 4260
REV 2
Ultra-Rugged Solar Mounting Solutions
©2020 U.S. Solar Mounts Corp. All Rights Reserved

2
CUSTOMER SUPPORT 2
1. Installer Responsibility 3
2. Tools that You’ll Need 4
3. Safety, Warnings & Cautions 5
4. Main Components & Overview 6
5. Locating the Array 7
6. Pole & Foundation Installation 9
7. Foundation Diagram 10
8. Array Assembly 11
9. Strong-Back & Angle Brace 12
10. 3160 / 4160 –Installing the Mounting Ribs 13
11. 3160 / 4160 –Installing the Panel 14
12. 3260 / 4260 –Installing the Panel Rails 15
13. 3260 / 4260 –Installing the Panels 16
14. Setting Array Elevation 17
15. Array Grounding 19
CUSTOMER SUPPORT
U.S. Solar Mounts products are designed to be simple and easy to install. If, for whatever reason,
you need help during installation, please give U.S. Solar Mounts’ customer support a call. We are
happy to help ensure each installation goes as smooth as possible. Have a comment or suggestion
on how we can improve your experience? Let us know. We do appreciate your feedback.
U.S. Solar Mounts
3498 Acorn Ave.
Sparta, WI 54656
[phone]
[e-mail]

3
1. Installer Responsibility
The installer is solely responsible for:
• Complying with all applicable local or national building codes, including any that may
supersede this manual.
• Ensure that U.S. Solar Mounts and other products are appropriate for the particular
installationandtheinstallationenvironment.
• Ensure that the selected mount can support the array under live load conditions.
• Use only U.S. Solar Mounts parts and installer-supplied parts as specified by U.S.
Solar Mounts. Substitution parts may void the warranty.
• Ensure proper array/structure grounding , including each module frame, the mounting
pole and each rail. Failure to provide proper grounding may result in damage to your
equipment or injury to personnel.
• Do not rely on the mounting pipe to act as a ground rod! It is not a reliable
substitute for a properly installed grounding electrode system.
• If you are unfamiliar with NEC compliant solar electric installations, consult with
the dealer that supplied your mount. They should have the skill and expertise to supply
you with the necessary wiring diagrams and the appropriate connection wire, grounding
equipment,junctionboxesandfusing.

4
2. Tools that You’ll Need
You’ll need a few basic hand tools in order to perform the installation of your array:
1. 2’ level(s)
2. Tape Measure
3. 1/2” Wrench
4. 9/16” Wrench
5. 3/4" Wrenches
6. Pencil or Sharpie
7. Wheelbarrow or Tub
8. Garden Hoe
9. Post Hole Digger
10. Shovel
11. Work Gloves
12. Compass or Smartphone App
In addition, the following materials will need to be acquired:
1. FOR 30 SERIES ONLY: 3” SCH40 Mounting Pipe (3-1/2” Outside Diameter)
2. FOR 40 SERIES ONLY: 4” SCH40 Mounting Pipe (4-1/2” Outside Diameter)
3. Concrete
4. 2x4s or other bracing material
5. 8’x5/8” Copper-Clad Ground Rod, Wire & appropriate clamps
NOTE: The Mounting Pipe MUST BE made of Steel.
DO NOT use a PVC Pipe for mounting the Array.

5
3. Safety, Warnings & Cautions
Before you begin any digging for the post, you MUST
make absolutely sure that there are no buried lines in
the area that you’ll be working. Buried utility lines can
be LETHAL if struck and / or damaged.
Use your head and PLEASE do not become a statistic!
We make every effort to remove sharp edges from our products. However, we highly
recommend wearing gloves when handling metal parts in order to avoid sharp edges.

6
4. Main Components & Overview
A
A
Upper & Lower Rib
F
Pivot Bolt
B
Rib Mounting Bolts
G
Slip fitter
C
Strong Back
H
Set Bolts
D
Brace Arm Bracket
I
SCH40/80 Steel Mounting Pole
E
Brace Arm
J
Solar Module

7
5. Locating the Array
South
West
3pm
9am
East
Noon
10am
2pm

8
Today
10 years from now

9
6. Pole & Foundation Installation
You should allow the concrete to cure for at least 24 hours before removing braces.
Adjust the pole to plumb
using a standard
construction level. Check
the pole in 2 locations 90
apart as shown.
Brace the pole with any
suitable lumber or readily-
available bracing material.

10
7. Foundation Diagram
Note:
Pole height may be adjusted
Down for Southern Latitudes.
Consult with US Solar Mounts
For assistance in determining
Proper pole height for your
Location.
72” MAX
48” MIN
GRADE
D=18”
Gravel Base
(Optional)
SCH40/80
Steel Mounting
Pole
Concrete -4k PSI MIN
Volume: 6 CU FT / 0.2 YDS

11
8. Array Assembly
North
Set Bolts
Steel Pole
1.
Unpack the Slip-Fitter Assembly and
lower it onto the top of the pole.
You’ll need to back the Set Bolts out in
order to install the Slip-Fitter onto the
pole.
MAKE SURE that the Angle Brace Tab is
aimed DUE NORTH.
2.
Once the Slip-Fitter is in place and
properly aligned, securely tighten the Set
Bolts.
Optional Step for High-Wind Areas
There is an extra 3/8” hole through the Slip-Fitter
located directly above the North Set Bolt. This
hole is for an Optional Roll Pin in extremely high-
wind areas.
1. Using the hole in the Slip-Fitter as a
guide, drill a hole through the side wall of
the pipe.
The hole has been sized for a 3/8” pin.
2. Insert a 3/8” Roll Pin into the hole.
3. Tap/drive the pin through the Slip-Fitter
and through the pole until it is nearly
flush. Take care not to damage the Slip-
Fitter’s paint.
Optional Roll Pin

12
9. Strong-Back & Angle Brace
Angle Brace
Pivot Bolt
Location
Slide Slot Nuts
Into Rail
StrongBack
Slot Nut
(enlarged)
NOTE: The aluminum Strong-Back has been factory cut-to-length for use with US Solar
Mounts supplied solar panels. If another source of module is used, the beam may need to be
trimmed to a shorter length. Most 60-Cell modules will have their holes spaced between 36”
and 44” apart. Both ends of the Rail will need to be trimmed to ensure the Pivot Hole remains
centered. A standard miter saw may be used to cut the aluminum.
Remember to secure/clamp the workpiece and CUT SLOWLY.
To calculate: Strong-Back Length = Module Hole-to-Hole center distance + 1.5”
If you have any questions at all, please give us a call & we will help you with it.
1.
Set the Strong-Back into the Slip-Fitter Assembly as shown below. Line up the holes and
insert the ½”-13 Pivot Bolt through the Slip-Fitter and Strong-Back. Hand Tighten ONLY.
The Rail needs to be able to pivot in order to set the array elevation later.
2. Slide the pre-assembled Angle Brace Bracket into the bottom North end of the Strong-
Back as shown.
3. Remove the bolt from the lower end of the Brace Arm.
4.
Swing the Angle Brace upward so that the lower end can be fastened onto the Angle Brace
Mounting Tab on the North side of the Slip-Fitter Assembly.
5.
Insert the bolt (previously removed) back through the lower hole in the Brace Arm and
mounting tab. Tighten the nut/bolt only finger-tight at this time.
6.
Tighten the Angle Brace Bracket bolts just tight enough to hold the StrongBack in place
for assembly.

13
10. 3160 / 4160 –Installing the Mounting Ribs
If you have a dual 60-Cell mount (3260 or 4260 TOP), jump to Section 11.
5/16” Hex Bolts
Mounting Rib
Before the Panels can be installed, the Ribs will need to be installed on both
ends of the Strong-Back.
The Ribs are fastened to the Strong-Back using four (4) 5/16-18 hex bolts &
lock-washers per rib.
1. Install the Ribs as shown below and tighten all 8 bolts securely.
Flanges must be
installed as shown,
toward the center.

14
Hex Bolts and
Serrated Flange Nuts
11. 3160 / 4160 –Installing the Panel
Skip the next Section and jump to Section 13 –Setting Array Elevation
1. Carefully unpack your solar module and set it onto the Ribs with the Junction Box on
the North end as shown below.
2. Line up the mounting holes on the back side of the module frame with the holes in the
Ribs.
3. Insert a 5/16-18 Hex bolt with a flat washer from the bottom of the Rib up through the
mounting hole in the back of the module frame.
4. Install a Serrated-Flange nut onto the bolt from the top side (under the module)
5. Once all 4 bolts have been installed, tighten them securely. The serrated nuts should
actually “dig in” to the aluminum module frame.
Refer to the diagram below for module installation.

15
1.
2.
3. Install four (4) carriage-head bolts, threads aiming down, into the holes on the top
flange of the Rail Bracket. Add a lock-washer and start a hex nut onto the threads on
the bottom side of the flange. Leave the nut at the end of the threads so the bolt is
loose.
4. Slide the Rails in across the top flange of the End Bracket so the carriage bolts slip
into the bottom slow. Make sure the two Rails meet at the center of the End Bracket.
5. Once each Rail is centered, tighten all hardware securely.
6. Repeat this process for the opposite Rail Bracket.
Refer to the diagram below for details.
12. 3260 / 4260 –Installing the Panel Rails
Carriage Bolts and Hex
Nuts w/ Lock Washers
Panel Rails
Slide Rails In
5/16” Hex Bolts
w/ Lock Washers
Rail Bracket

16
Carriage Bolts and Serrated
Flange Nuts
Refer to the diagram below for details.
13. 3260 / 4260 –Installing the Panels

17
Your last assembly step is to set the Elevation of the array. The optimum year-round
tilt angle for a solar array is determined by your latitude North of the equator. You can
find your latitude in a multitude of different ways.
1. A GPS or Smart-Phone App
2. Google Earth
3. Almost any mapping site like Google Maps, Bing Maps, MapQuest, etc.
4. The map on the following page will give you a rough idea.
Latitudes for various cities in the U.S.
City
Latitude North
Minneapolis, MN
44
Des Moines, IA
41
Tulsa, OK
36
Chattanooga, TN
35
Dallas, TX
32
Cuero, TX
29
Orlando, FL
28
Although accuracy is nice, please keep in mind that if you are off by 5-10, it will not be the
end of the world. In fact, it will likely be barely noticeable.
Once you’ve determined what angle you’d like to set your array to, it’s time to tilt it up.
1. Loosen the 4 Brace Arm Bracket bolts on the bottom of the Strong-Back.
2. Tilt the array to your desired Elevation.
3. Securely tighten the Brace Arm Bracket bolts
4. Securely tighten the hardware on the Upper & Lower end of the Brace Arm.
5. Securely tighten the large Main Pivot Bolt. The “ears” on either side of the
Strong-Back should clamp tightly against the side of the Strong-Back.
Usually Free Smart Phone App
Generally, $10 or Less
Range from $35 to $125
14. Setting Array Elevation
There are a variety of ways to measure the angle of your array, most of which are very
inexpensive and some are free.

18
A few notes on Summer vs Winter Elevation Settings:
The previous page briefly describes how to find the optimum “year-round” array tilt. While this
setting may work for nearly all situations, it may be possible that a different tilt angle is needed
for specific situations.
For example, someone living in Wisconsin or Maine using a US Solar Mounts SD Aerator may
be more interested in keeping an area of their lake free of ice in the Winter. De-icing around
gates or spillways could be very important to them. Either way, folks in the North will have to
deal with snow accumulation on the array. They may want to INCREASE (steepen) the tilt angle
to favor Winter production when the sunangle is very low. Theincreased tilt angle willalso assist
with shedding snow from the array. It is very common to have tilt angles of 50-60on Northern
installations.
Installation sites in the Southern part of the US may have completely different solar production
goals at different times of the year. For instance, if the primary goal is to prevent fish kill in a
farm tank during the super-hot months of July & August, they may want to DECREASE (flatten)
the tilt angle of their array for greater summertime production. If they could, the Largemouth in
your tank would thank you for it.
If you would really like to “see” the effect that changing tilt angle has, go out and play with the
array! Pick a nice, sunny day around noon. It only takes a minute to loosen the Angle Brace
Bracket and the Main Pivot Bolt. Make sure to tighten everything up again when you’re finished.

19
15. Array Grounding
A properly installed solar array of any size or configuration needs to be solidly grounded.
You should not rely only on the mounting pole for proper or effective grounding.
Grounding of your pole top should accomplish the following:
1. Bonding the solar module frame to the rack itself, and
2. Grounding the rack to an Earth Ground via a Grounding Electrode Conductor (GEC).
The components required to properly ground an array may vary from one jurisdiction to
another and are normally supplied & installed by the installer.
The diagrams below show the basic grounding system. The GEC is shown in green for
illustration purposes but is normally a bare #8 Stranded copper conductor.
Note: Insulated wire can be used but must be stripped at each termination point.
Single Panel GND Wire Route
Module Frame Ground Lug
StrongBack Ground Lug
Ground Rod Clamp
5/8”x8’ Rod
Rod Clamp
Foundation
StrongBack
To Rod
Module Frame
Rib or Rail
2nd Module
#8 Bare Stranded CU

20
Assembly of the mount is now complete. The installer is responsible for ensuring proper wiring of
the modules for the given project. If being used for a US Solar Mounts SLA, refer to your SD
Series Instruction Manual for array wiring.
If you have any questions about the installation of your solar array, please don’t hesitate to
contact us. We’ll answer your questions & walk you through any parts that you need help with.
Completed 3160/4160
Completed 3260/4260
One last check…
Take a minute to go over your array one
more time to check for loose hardware.
Don’t be afraid to bang on it a little bit &
listen for loose parts.
Put your hands on each fastener one more
time.
It’s far better to find a loose bolt now
versus finding a solar panel laying in your
yard after a wind storm.
[email protected]