UNIRAC PoleTops 5004 Series User manual

UniRac welcomes input concerning the accuracy and user-friendliness of this publication. Please write to [email protected]. May 2007
© 2007 by UniRac, Inc. All rights reserved.
THE STANDARD IN PV MOUNTING STRUCTURES
U.S. Des. Patent No. D496,249S.
Other patents pending.
Installation Manual 507.6
Thank you for purchasing a UniRac product. Please review
this manual completely before proceeding. This rack mounts
to a 6-inch (150 mm) Schedule 40 or 80 steel pole, outside
diameter 6.625 inches (168.3 mm).
Series 5014 models include a high wind brace (illustrated above).
All Series 5004 models accommodate the high wind brace (item
no. 990365) as an option.
The installer is solely responsible for:
• complying with all applicable building codes, in-
cluding any that supercede these instructions;
• pole installation appropriate for local wind and soil
conditions;
• using only UniRac parts and installer-supplied
parts as specified by UniRac (substitution of parts
will void the warranty);
• installing all electrical aspects of the PV array.
Series 5004 and 5014
Double Row 6-Inch Pole Top with SolarMount®HD Rails

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2
Installation Manual 507.6 Series 5004 and 5014 PV PoleTops®
High Wind Brace Parts List (Included with Series 5014 and models.
Optional with Series 5004 models. (Parts are illustrated on p. 4).
Wrench Recommended
Part Qty size torque, ft-lbs (N-m)
Pole bracket 1
Leg strut, 75˝ 2
Rail strut, 106˝ 1
L-foot 4
U-bolt, 3⁄8˝ x 6
5⁄8˝ 1
Hexhead bolt, 3⁄8˝ x 3⁄4˝ 4
9⁄16˝ 30 (40)
Hexhead bolt, 3⁄8˝ x 1
1⁄4˝ 8 9⁄16˝ 30 (40)
Flat washer, 3⁄8˝ x 1
1⁄4˝ 8
Strut nut, 3⁄8˝ 8
Flange nut, 3⁄8˝ 6
9⁄16˝ 30 (40)
Basic Parts List for All Models
(Parts are illustrated on pp. 2–3).
Wrench Recommended
Part Qty size torque, ft-lbs (N-m)
Can and strut
assembly (p. 3)
Pole can, 6˝ 1
Pole can set screws, 7/16˝, 12-point
square head,
3⁄8˝ x 1˝ 4 socket 25 (32)
Tilt strut, left 1
Tilt strut, right 1
Strut plate 2
Hex bolt, 3⁄8˝ x 9˝ 1
Carriage bolt, zinc plated,
3⁄8˝ x 11⁄2˝— Grade 5 6 9⁄16˝ 35 (46)
Fender washer, 3⁄8˝ x 11⁄2˝ 6
Fender washer, 3⁄8˝ x 1˝ 6
Mechanical lock nut, 3⁄8˝ 7 varies
Rail and cross tube
assembly (p. 4)
SolarMount HD rail 4
Square cross tube, 3˝ 2
Square U-bolt, 3⁄8˝ x 3˝ 12
Plate washer 12
Flange nut, 3⁄8˝ 24
9⁄16˝ 30 (40)
Module mounting (p.5)
Module mounting clip 4*
Module bolt, 1⁄4˝ x 5⁄8˝ 4*
7⁄16˝ 15 (20)
Flat washer, 1⁄4˝ 4*
Flange nut, 1⁄4˝ 4*
7⁄16˝ 15 (20)
* Per module to be mounted. Series 5014 and 5004 racks include clips and
hardware to mount from 4 to 12 modules, depending on the model number.
Stainless steel hardware can seize up, a process called
galling.To significantly reduce its likelihood, (1) apply
lubricant to bolts, preferably an anti-seize lubricant, available
at auto parts stores, (2) shade hardware prior to installation,
and (3) avoid spinning on nuts at high speed. See Installation
Supplement 910, Galling and Its Prevention, at www.unirac.com.

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Installation Manual 507.6 Series 5004 and 5014 PV PoleTops®
Attach struts to pole can
On each side of the can, install the center 3/8-inch
carriage bolt, pushing it through the square hole from
inside the pole can. (The can may now be placed on the
pole and set screws finger tightened or assembly may
continue off pole, depending on installer preference.)
Slide the remaining four carriage bolts into the slots on
both sides of the can.
Carriage bolts must be lubricated with anti-seize
to achieve design bolt tension during final adjust-
ment.
Loosely secure strut plates and fender washers with the
mechanical lock nuts. Do not tighten the lock nuts until
final adjustment.
Tilt struts can be tilted in one direction only.
Verify that they are installed to tilt toward the
noon sun. If not, reverse the position of the two
tilt struts.
Tilt strut
Set
screws
Pole can
Carriage bolts
lubrication
mandatory
Strut
plate
Fender washers, 3/8˝ x 11/2˝
Mechanical lock nuts
torque (35 ft-lbs) during final adjustment
Secure pole can
This step may be taken immediately after tilt strut
assembly or following final adjustment, depending on
installer preferance.
Using a 3/16-inch drill, make pilot holes through the two
sides of the can and the Schedule 40 mounting pole.
Expand the holes with a 13/32-inch drill.
With three washers on each side, pass the 3/8x 9-inch
Grade 8 bolt through can an pole and secure with the
remaining 3/8-inch mechanical lock nut. Torque to 45
foot pounds.
Mechanical lock nut
torque (45 ft-lbs)
Fender washers, 3/8˝ x 1˝

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Installation Manual 507.6 Series 5004 and 5014 PV PoleTops®
Attach cross tubes and rails
Attach square cross tube to tilt struts using four square U-bolts and
U-bolt plates, secured with 3/8-inch flange nuts. Torque to 30 foot-
pounds (40 newton-meters).
Add rails using the remaining eight sets of square U-bolts and U-
bolt plates. Make sure the rails are parallel and that the two outer
rails are equidistant from the center of the cross pipe. Space the
inner rails following the illustration at right. Finger tighten 3/8-inch
flange nuts on U-bolts.
SolarMount
HD rail Square
cross tube
Square U-bolt
Rail cross section
A
For each pair of rails, the distance (A) between
the rails’ outer edges equals the distance
between the centers of the module mounting
holes minus one inch (2.5 cm).
Plate washer
Flange nut, 3/8˝
Plate washer
Flange nut, 3/8˝

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Installation Manual 507.6 Series 5004 and 5014 PV PoleTops®
Final adjustment
With an assistant supporting the rack, loosen the lock nuts on the tilt struts.
Bring the rails level to allow clear access to the 3/8-inch set screws on the pole
can.
Loosen the set screws and adjust the direction of the entire array on the pole.
Once satisfied with the array’s alignment, use a 7/16-inch 12-point socket
wrench and torque all four set screws to 25 foot-pounds (32 newton-meters).
Adjust the array to the desired tilt angle. Torque lock nuts to 35 foot-pounds
(46 newton-meters).
After all six lock nuts are torqued, repeat the torquing procedure at
least once.
Install modules
Secure each PV module using four clips.
Be sure modules are centered along the
length of the rail. Initially finger tighten
1⁄4-inch flange nuts. When all modules
are in place and aligned, torque 1⁄4-inch
flange nuts to 15 foot-pounds (20 newton-
meters).
When modules are centered along the
rails and secure, tighten the 3/8-inch
flange nuts holding the rails to the square
cross tubes. Torque to 30 foot-pounds (40
newton-meters).
Flat Washer: Most PV
modules have mounting
holes small enough to
secure the module bolt
without the washer. Use
the washer with larger
holes. If in doubt, use the
washer.
PV module
Module bolt
Flange
nut, 1/4˝
Module
mounting hole
Module
mounting
clip

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Installation Manual 507.6 Series 5004 and 5014 PV PoleTops®
Mounting Pole Requirements
Imperial
Total Design
module wind Hole In-ground Concrete
area speed diameter pole depth volume
60 sq. ft. 90 mph 24 in. 46 in. 12 cu. ft.
60 sq. ft. 120 mph 30 in. 52 in. 21 cu. ft.
70 sq. ft. 90 mph 24 in. 54 in. 14 cu. ft.
70 sq. ft. 120 mph 30 in. 60 in. 24 cu. ft.
80 sq. ft. 90 mph 24 in. 60 in. 16 cu. ft.
80 sq. ft. 120 mph 30 in. 68 in. 28 cu. ft.
90 sq. ft. 90 mph 24 in. 68 in. 18 cu. ft.
90 sq. ft. 120 mph 30 in. 76 in. 31 cu. ft.
100 sq. ft. 90 mph 24 in. 76 in. 20 cu. ft.
100 sq. ft. 120 mph 30 in. 82 in. 34 cu. ft.
The installer is solely responsible for use of these general guidelines. The
following variances can affect your installation:
• The required diameter and depth of the hole depend on soil type. Sandy
soil, for example, requires more concrete.
• The diameter and depth of the hole should also be increased wherever
wind speeds exceed those listed in the table below, particularly if the site
is open and unprotected. Note the wind loading and exposure assump-
tions in the table note below.
• Poles taller than 6 feet (1.8 meters) require that the depth of the hole be
increased.
If in doubt, consult a professional civil engineer who is familiar with local soil condi-
tions and wind loading requirements.
1. Dig the hole at least 4 inches (10 cm) deeper than required under “In-
ground pole depth” in the table below. Fill the extra depth with gravel to
allow water drainage.
2. Take some measure to prevent the pole from turning in the concrete during
high winds.
3. Brace the pole so that it is plumb in the hole. Pour concrete around it,
filling the hole to ground level. Add an inch or two (3 to 5 cm) of extra
concrete above the hole. Trowel the concrete so that it slopes up to the
pole (see table illustration).
4. Allow the concrete to set up for at least 24 hours before installing your PV
Poletop.
In-ground
pole depth
Gravel
C
o
n
c
r
e
t
e
Schedule 40
steel pole
Metric
Total Design
module wind Hole In-ground Concrete
area speed diameter pole depth volume
6 sq. m 150 km/h 60 cm 120 cm 0.34 m3
6 sq. m 200 km/h 70 cm 155 cm 0.59 m3
7 sq. m 150 km/h 60 cm 140 cm 0.39 m3
7 sq. m 200 km/h 70 cm 175 cm 0.67 m3
8 sq. m 150 km/h 60 cm 160 cm 0.45 m3
8 sq. m 200 km/h 70 cm 205 cm 0.78 m3
9 sq. m 150 km/h 60 cm 175 cm 0.50 m3
9 sq. m 200 km/h 70 cm 225 cm 0.87 m3
11 sq. m 150 km/h 60 cm 215 cm 0.60 m3
11 sq. m 200 km/h 80 cm 200 cm 1.00 m3
Assumptions:The pole extends no more than 6 feet (1.8 meters) above ground. Design wind speeds assume 29 psf wind force at 90 mph (150
km/h) and 51 psf wind force at 120 mph (200 km/h), which correspond to Exposure Category C of the International Building Code, terrain that
is flat and generally open extending one-half mile (800 meters) or more from the site in any quadrant.
Mounting pole guidelines for UniRac PV PoleTops®

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Installation Manual 507.6 Series 5004 and 5014 PV PoleTops®
A high wind brace is standard with all
Series 5014 PV PoleTops. For all Series
5004 PV PoleTops, it may be installed as
an option (item no. 990365).
Slide the heads of the 3/8x 3/4-inch
hexhead bolts into the footing slots of
the SolarMount HD rails. Attach L-feet
6 to 12 inches from the ends of the rails
and finger tighten flange nuts. Attach rail
strut with four of the 3/8x 11/4-inch bolts
and strut nuts. Finger tighten.
Attach pole bracket to pole. Finger
tighten flange nuts.
Attach leg struts to pole bracket
and rail strut with remaining 3/8x
11/4-inch hexhead bolts and strut
nuts. Place leg struts just outside
the inner rails. Finger tighten.
Adjust to make leg struts
parallel to the ground.
Be sure that L-feet are
vertical.
Torque all 3/8-inch hardware to 30
foot-pounds (40 newton-meters).
If desired for aesthetics, trim rail strut
and leg struts.
U-bolt
Pole bracket
Leg struts
Rail strut
Bolt heads slide
into rail footing slots
Bolts, 3/8˝ x 11/4˝
(to strut nut)
Washer
Bolt, 3/8˝ x 3/4˝
(to flange nut)
Flange nut
Strut nut
Attach leg struts parallel to the
ground just outside the inner rails
High wind brace

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10 year limited Product Warranty
UniRac, Inc., warrants to the original purchaser
(“Purchaser”) of product(s) that it manufactures
(“Product”) at the original installation site that
the Product shall be free from defects in material
and workmanship for a period of ten (10) years,
from the earlier of 1) the date the installation
of the Product is completed, or 2) 30 days after
the purchase of the Product by the original
Purchaser.This Warranty does not cover damage
to the Product that occurs during its shipment,
storage, or installation.
This Warranty shall be VOID if installation of
the Product is not performed in accordance
with UniRac’s written installation instructions,
or if the Product has been modified, repaired, or
reworked in a manner not previously authorized
by UniRac IN WRITING, or if the Product is
installed in an environment for which it was
not designed. UniRac shall not be liable for
consequential, contingent or incidental damages
arising out of the use of the Product by the
Purchaser under any circumstances.
If within the specified Warranty period the
Product shall be reasonably proven to be
defective, then UniRac shall repair or replace
the defective Product, or any part thereof,
in UniRac’s sole discretion. Such repair or
replacement shall completely satisfy and
discharge all of UniRac’s liability with respect to
this limited Warranty. Under no circumstances
shall UniRac be liable for special, indirect or
consequential damages arising out of or related
to use by Purchaser of the Product.
Manufacturers of related items, such as PV
modules and flashings, may provide written
warranties of their own. UniRac’s limited
Warranty covers only its Product, and not any
related items.
THE STANDARD IN PV MOUNTING STRUCTURES
1411 Broadway NE, Albuquerque NM 87102-1545 USA • 505.242.6411 • Fax [phone]
Installation Manual 507.6 Series 5004 and 5014 PV PoleTops®