UNIRAC EcoFoot5DTM User manual

INSTALLATION GUIDE
UNIRAC Code-Compliant Installation Manual
© 2020 by Unirac, Inc. All rights reserved.
UNIRAC welcomes input concerning the accuracy and user-friendliness of this publication. Please write to [email protected]om. PUB2020OCT31
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM

INSTALLATION GUIDE
*If provided refer to construction drawings for project specifi c details. Construction
drawings have precedence over these installation guidelines.
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
WARNINGS AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL APPLICATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
SYSTEM INSTALLATION STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
STEPPED ARRAY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
MODULE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ROOF ATTACHMENT WITH STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-21
GROUNDING AND BONDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CODE COMPLIANCE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MECHANICAL LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
COMPATIBLE MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

INSTALLATION GUIDE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
Legal Notices
©2017 Unirac®, Inc. Unirac® and EcoFoot2+® are registered trademarks of Unirac, Inc. EcoFoot5D™ is a trademark of
Unirac, Inc., registration pending.

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
1
INTRODUCTION
INTRODUCTION
EcoFoot5DTM is a 5-degree ballasted racking system designed to fi t more modules on a roof, maximizing power density. The modular de-
sign is built on the proven, industry-preferred, beautifully simple and fast-to-install modular technology of the EcoFoot platform and sister
product, EcoFoot2+.
EcoFoot5D consists of fi ve simple components. Installation is accomplished in six simple steps. Much of the installation is tool-less.
EcoFoot5D Bases self-align, requiring only two chalk lines. The PV module installation automatically moves the Bases into perfect place-
ment. Inter-row ballast placement and easy-reach wire management provide superior accessibility during and after installation.
Stackable Bases enable the transport of up to 290kW of Bases on 1 standard pallet, streamlining logistics. The combined effect of simplic-
ity, maximum density, and minimized shipping, storage and transporting costs results in an ultra cost-effective racking solution.
FIELD SUPPORT CONTACT INFORMATION
Unirac proudly offers dedicated engineering expertise and superior customer support. For questions about the installation procedures or a
specifi c application, please visit www.unirac.com.
INSTALLER RESPONSIBILITY
The installer is solely responsible for:
• Utilizing all necessary safety equipment, as required by applicable rules and regulations.
• Complying with all applicable local and national building codes, including any that may supersede this manual.
• Ensuring that Unirac® EcoFoot5D™ and other products are appropriate for the specifi c installation and are designed for the installa-
tion environment.
• Ensuring that the roof, its rafters, connections, and other structural support members can support the array under all conditions.
• Maintaining the waterproof integrity of the roof including selection of appropriate fl ashing if the system is being installed using at-
tachments.
• Ensuring safe installation of all electrical aspects of the entire system.

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
2
INTRODUCTION
DISCLAIMER OF LIABILITY
Unirac® does not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of, or in any way connect-
ed with installation, operation, use, or maintenance by using this manual.
Unirac assumes no responsibility for any infringement of patents or other rights of third parties, which may result from use of modules. No
license is granted by implication or under any patent or patent rights. The information in this manual is believed to be reliable, but does
not constitute an expressed and/or implied warranty.
Unirac reserves the right to make changes to the product, specifi cations, data sheets and this manual without prior notice. This document
is not prescriptive regarding safety and does not purport to address all the safety concerns that may arise with its use. Contractors should
become familiar with all applicable safety, health, and regulatory requirements before beginning work.
Unauthorized fi eld modifi cation of Unirac components or assemblies may affect Unirac warranty coverage. Provide written drawings for
Unirac’s review, comment and approval prior to attempting any fi eld modifi cations.

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
3
WARNINGS AND SAFETY
WARNINGS AND SAFETY
Both electrical and roofi ng knowledge are required to correctly and safely install a solar photovoltaic system. Only qualifi ed and certifi ed
installation professionals should install EcoFoot5D. Failure to follow the methods and procedures outlined in this guide may result in
injury and/or damage to property.
Carefully read this guide before starting any work. Store a copy of this guide on the job site at all times and contact Unirac with any in-
stallation questions related to EcoFoot5D.
WARNING
Please note the following warnings when installing EcoFooot5D:
• EcoFoot5D components fi t together tightly and could cause pinch injuries.
• EcoFoot5D components may be hot to the touch if left in the sun.
Please follow the safety requirements below when installing EcoFoot5D:
• Always keep children and unauthorized people away from work areas.
• Always wear required OSHA approved Personal Protective Equipment (PPE).
• Always use insulated tools when working with or near electrical systems.
• Always provide OSHA approved fall protection for all installation personnel.
• Never wear jewelry during mechanical and electrical installation work.
• Never work in rain, snow or extremely windy conditions.
• Never leave a module unsupported or unsecured on the roof.
• Never install broken photovoltaic modules.

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
4
GENERAL APPLICATION NOTES
ECOFOOT5D GENERAL APPLICATION NOTES
Site-Specifi c System Design: Unirac provides drafting services on all EcoFoot5D projects. This service produces a site-specifi c design pack-
age with an Engineered Stamped Layout including detailed ballast plan and bill of materials.
Roof Type: EcoFoot5D is designed to mount photovoltaic modules to a range of roof surfaces, including: EPDM, TPO, PVC, Mineral Cap
Sheet (a.k.a. Rolled Asphalt), Tar and Gravel.
Roof Slope Range: 0-7 degrees maximum, 3-degree limit for unattached seismic.
Wind Zone: EcoFoot5D is designed to mount photovoltaic modules on fl at roof surfaces with a maximum pitch of 7 degrees in areas with
extreme wind conditions. Please contact Unirac for clarifi cation or assistance.
Installation Requirements: EcoFoot5D is a ballasted photovoltaic racking designed as a system. The system requires all EcoFoot5D
components, the specifi c module, and ballast placement prescribed in the PE stamped design. The absence of any of these elements in
any given sub-array could present a compromised condition on the roof. Arrays shall not be left unattended in such a state during an
installation.
This install guide offi cially documents the components used and proper methods for an EcoFoot5D installation. Bonding elements are
incorporated into EcoFoot5D components. As the system is built on the roof, components and modules are bonded together. Specifi c steps
to ensure a bonded system are described through the installation guide. It is the installer’s responsibility to ensure that the system is
safely and properly installed, and that the system is bonded back to a fi nal ground point.
When wiring the array, keep bare copper from contacting bare aluminum.
Thermal and Seismic Design Requirements: EcoFoot5D is a fl exible and expandable design that accommodates various array geometries.
Maximum widths for arrays are as follows:
• 60-cell modules, 26 modules in a row
• 72-cell modules, 22 modules in a row
Minimum spacing between sub-arrays is 6”. Site specifi cs may further limit array sizes and spacing.

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
5
GENERAL APPLICATION NOTES
Seismic and Uplift Design Requirements: EcoFoot5D can be attached when required by seismic and uplift conditions as specifi ed by the
Authority Having Jurisdiction (AHJ). Use the method required for the specifi c Fire Code Rating of the PV module.
Re-Inspection: Unirac recommends periodic re-inspection of the installation for loose components, loose fasteners, and any corrosion, such
that if found, the affected components are to be immediately replaced. Any components showing signs of damage that compromise safety
shall be replaced immediately
Compatible Modules: Unirac has evaluated many photovoltaic modules for installation compatibility with the EcoFoot5D ballasted racking
system. A list of compatible modules may be found on "Compatible Modules" page
UL2703 Qualifi cation: In cases where UL 2703 certifi cation is required, the EcoFoot5D system conforms to the UL2703 Standard for
grounding and bonding and fi re ratings. The EcoFoot5D system may be used to ground and/or mount a PV module complying with
UL1703 only when the specifi c module has been evaluated for grounding and /or mounting in compliance with the included instructions.
EcoFoot5D system is to be installed over a fi re resistant roof covering rated for the application. EcoFoot5D racking maintains a Class A fi re
rating when installed in landscape orientation according to the installation instructions, on a low slope roof Class A roof with Type 1 and
Type 2 modules. When installing Type 2 modules a Ballast Tray is required to maintain the Class A fi re rating. For system confi gurations
meet the requirements to maintain a Class A fi re rating for Type 2 modules, the following module types also maintain a Class A fi re rat-
ing; Type 3 PV models with an OEM factory-attached PV metal frame, Type 19, Type 22, and Type 25. Type 29 and Type 30 modules whose
encapsulation thickness matches the criteria for Type 3 modules are also an approved fi re types. Contact Unirac with any questions about
fi re type compatibility.
For roofs with lower fi re ratings, the existing rating is maintained when EcoFoot5D is used.
At this time, the EcoFoot5D system is undergoing further testing pertaining to mechanical loading with specifi c modules. Further informa-
tion about Unirac’s UL2703 conformance may be found in Appendix A of this manual.

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
6
SYSTEM COMPONENTS
EcoFoot5D Base
Clevis Pins
Mid-Support Upper
Universal Clamp Lower
Wind Defl ector
Mid-Support Lower
Universal Clamp Upper
Ballast Tray
5/16” Thread-Forming Screw
1
4
7
2
5
8
3
6
9
Universal Clamp Upper
Ballast Tray
3
6
Hardware Required
All required hardware is included.
Tools Required
½” Deep Socket
Calibrated Torque Wrench
Torque Settings
14 ft-lbs on all 5/16” Fasteners

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
7
SYSTEM COMPONENTS
S.NO. DESCRIPTION PART NUMBER
1 EcoFoot5D Base ES10490
2 Universal Clamp Lower ES10459
3 Universal Clamp Upper ES10458
4 Clevis Pins ES10476-CP
5Wind Defl ector
70" ES10494
82" ES10496
92.25" ES11026
6Ballast Tray
71" ES10486
83" ES10488
93.25" ES11025
7 Mid-Support Upper ES10481-CP
8 Mid-Support Lower ES10482-CP
95/16” Thread-Forming Screw ES10456-CP

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
8
SYSTEM INSTALLATION STEPS
Step 1 – Install Pre-assembled Universal Clamps into Bases
• Place Lower and Upper Universal Clamp into EcoFoot5D Base as shown.
• Push Clevis Pins completely into EcoFoot5D Base to secure Rocker.
Step 2 – Position Array
• Snap two chalk lines on roof denoting outside edges of the EcoFoot5D
Bases, per project drawing. Start from the north or south edge. Ensure
chalk lines are square.
• Place EcoFoot5D Bases in approximate position throughout the array.
Installation Tips
• Only install Clamps where modules will rest.
• See Step 3 for correct placement and orientation of Clamps.
Installation Tips
• As you build the array, panels will space the Bases. Roughly place a few
rows of Bases at a time so that they are within reach of fi nal location.
Note: The Upper Clamp includes a post and nut to install the Wind
Defl ector as shown in Step 6.

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
9
Step 3 – Secure PV Modules onto Bases
• Place PV module onto EcoFoot5D Base.
• Space modules ½” apart using alignment marks located on the Clamps.
Torque Nuts to 14 ft-lbs using a 1/2" deep socket.
Step 4 – Install Mid-Support
Locate module center point +/-1”
using PV module cell lines.
Slide the Upper and Lower Mid-Support
slots onto module frame.
Press Upper down to sit fl at on the
roof.
Press Lower down and snap onto
tongue of upper.
Installation Tips
• After Step 3, wiring can be routed and secured.
• Standard wire clips or cable ties (not included) can be inserted into slots
along Base edge
Nut
Module
Base
Nut
Upper & Lower
Mid-Support
Note: Mid Support kits are used between rows and on the North and South array edges where ballast trays will be installed.
PV Module
Center Point
SYSTEM INSTALLATION STEPS

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
10
Step 5 – Install Ballast Tray and place ballast blocks on Tray
• Slide tray into retention clips located on the Base by sliding the Tray
along the east-west direction.
• Secure tray to Mid-Support using 5/16” thread forming screw provided
with Mid-Support Kit. Torque Screw to 14 ft-lbs.
• Place ballast (not included) in a single layer evenly dispersed along the
length of Ballast Trays. Apply ballast per the ballast plan specifi ed in the
PE Certifi ed Ballast Plan – Sheet S-1.0.
Step 6 – Install Wind Defl ector
Place Wind Defl ectors into slot on EcoFoot5D Base and attach to Rocker
using Nut provided.
Torque Nut to 14 ft-lbs using a ½” deep socket.
Application of anti-seize on threaded post recommended.
Rocker Nut
Ballast Tray
Ballast Tray
5/16" Screw
Base
Retention
Clips
Base
Retention
Clip
Wind Defl ector
SYSTEM INSTALLATION STEPS

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
11
The north row of EcoFoot5D arrays can be installed with Bases tucked under the modules using either of the methods described here.
EcoFoot2+ Bases can be tucked under the north edge of EcoFoot5D arrays as shown in the diagram.
• Tilt angle of North row will be 2 degrees higher than rest of array.
• Additional EcoFoot2+ Bases may be added to the center of the module frame if required for high snow loads or to hold additional ballast blocks.
METHOD A: EcoFoot2+ BASES AND WIND DEFLECTORS
METHODS OF NORTH ROW INSTALLATION
METHOD A: EcoFoot2+ BASE TUCKED ON NORTH EDGE
SYSTEM INSTALLATION STEPS

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
12
EcoFoot5D Bases can be tucked under the north edge of the north row and connected to anchored Strut. Strut runs East/West. See diagram below.
• Do not use Mid Supports and Ballast Trays on
north row of tucked EcoFoot5D Bases.
• An additional EcoFoot5D Base may be added to
the center of the module frame if required for
high snow loads. The additional center Base does
not need to be attached to the Strut.
Method B: EcoFoot5D Bases Attached
METHOD B: EcoFoot5D BASE TUCKED ON NORTH EDGE
DETAIL A:
Roof Attachment
DETAIL B:
Tucked EcoFoot5D Base on North Edge
NOTE:
Some EcoFoot5D arrays are designed to be fully
attached with strut running North/South. For fully
attached systems, Mid supports and Ballast Trays
are not needed. North edge Bases can be tucked and
additional East/West strut attachment is not needed.
SYSTEM INSTALLATION STEPS

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
13
In solar arrays, at the outer edge of the array often a single Base is clamped to two PV modules on one row and a single PV module on the opposite row, creating
a stepped edge. Clamps securing a single PV module are positioned differently than Clamps securing two PV modules. Follow the Clamp positioning instructions
below:
INSTALLATION OF CLAMPS FOR STEPPED ARRAY
Example of one confi guration of Stepped Array.
At array edge, South Row has one less PV module than North
Row, creating a stepped edge. Alternatively, Stepped Arrays may
have the single PV module on the North Row.
Stepped Array Edge
Clamp secures single PV module
Clamp secures two PV modules
STEPPED ARRAY INSTALLATION

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
14
CLAMPING TO SECURE SINGLE MODULE OF STEPPED ARRAY
CLAMPING TO SECURE TWO MODULES OF STEPPED ARRAY
• Position module to align with positioning dot at outer edge of
Clamp. This will engage 1 ¾" of Clamp with module frame. Align
Base as needed to position Clamp. Base will be slightly out of par-
allel.
Torque Nut to 14 ft-lbs using a 1/2" deep socket.
Position Clamp in typical two-module clamping position and
torque Nut.
Torque the nut to 14 ft-lbs.
1 ¾"
Positioning Dots
Clamp Securing Single PV Module
Clamp Securing Two PV Modules
STEPPED ARRAY INSTALLATION

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
15
MODULE REMOVAL
MODULE REMOVAL
If a module is to be removed from an array, the following steps must be taken.
STEP A: Determine module to be removed
Identify and mark the module to be removed.
STEP B: Install ground lug on adjacent modules
Install a WEEB Lug 6.7 on both modules adjacent to the module to be removed. Utilize the grounding hole on the frame of the module.
STEP C: Connect Bonding Jumper
Lay a bare #6 CU conductor into the two lay in lugs connected to the adjacent modules. Tighten lay-in lug terminal screw onto the conductor and torque to 7 ft- lbs.
When wiring the array, keep bare copper from contacting bare aluminum.
CAUTION
• Module removal may disrupt the bonding path and
could introduce the risk of electric shock.
• See Grounding and Bonding Paths section to determine
when module removal may disrupt the bonding path.
• Follow Steps A through C to maintain the bonding path.
Modules should only be removed by qualifi ed persons
in compliance with these instructions.

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
16
ROOF ATTACHMENT WITH STRUT
INSTALLATION OF ROOF ATTACHMENT WITH STRUT TOOLS REQUIRED
Torque fasteners to 14 ft-lbs.
Overview of Attachment System
COMPONENTS
EcoFoot Roof to Strut Hardware Kit
P/N: ES10843
EcoFoot Strut to Module Hardware Kit
P/N: ES10844
Strut (1-5/8” x 1-5/8”) Roof Attachment
Length specifi ed on array layout. Specifi ed based on roof type.
Note:
Roof Attachments require roofi ng screws, available by others. Check with
building engineer or attachment manufacturer for screw requirements.
1. 1/2" Deep Socket
2. 9/16" Deep Socket
3. 1/2" Box End Wrench
4. Calibrated Torque Wrench
5. Power Drill with 3/8" Drill Bit
Note: P/N: Part Number

INSTALLATION GUIDE PAGE
HIGH DENSITY 5-DEGREE
BALLAST RACKING SYSTEM
17
ATTACHMENT WITH STRUT
Strut runs North/South under PV modules, near the center of the module, placed as indicated on array layout. Strut does not connect to EcoFoot2 Bases. Strut is
attached to Roof Attachment, low or south edge of PV modules and Wind Defl ector.
STEP 2:
Position Strut under and near center of PV module
in line with center slots on Wind Defl ector. Posi-
tion Strut throughout the array as shown on array
design layout.
STEP 1:
For EcoFoot5D, drill a 3/8" through hole in the
wind defl ector for strut strap installation in
step 10. The center of the hole to be located 5/8"
above the bottom edge of the defl ector
STEP 3:
Determine which side of Strut you will install Roof
Attachment.
Mid supports will be installed slightly off center and
opposite of roof attachment to allow room for roof
attachment hardware.
ROOF ATTACHMENT WITH STRUT