UNIRAC PoleTops 5001 Series User manual

© 2004 by UniRac, Inc.
All rights reserved.
Pub 040625-3ii
July 2004
UniRac welcomes input concerning the accuracy and user friendliness of
this manual. Please write to [email protected].
Series 5001 Single Row 3-Inch Pole Top
with SolarMount™ HD Rails
Installation Manual 524
U.S. and other patents pending.
Thank you for purchasing a UniRac. Please review this
manual completely before proceeding.
This rack is intended for a 3-inch Schedule 40 steel
pole (O.D. 3 1/2inches).
Assembly order is not critical. Work from the pole
outward or attach PV modules to rails before mount-
ing the array to the pole.
The installer is solely responsible for:
• complying with all applicable building
codes, including any that supercede these
instructions;
• pole installation appropriate to 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.
Parts List
Wrench Recommended
Part Qty. size torque (ft-lbs)
SolarMount rail 2
Cross pipe 1
Pole clamp 2
Pole cap 1
Hexhead bolt, 7⁄16˝ 4 5⁄8˝ 30
Lock washer, 7⁄16˝ 4
Nut, 7⁄16˝ 4 9⁄16˝ 30
Saddle 2
U-bolt, 3⁄8˝ 2
Flange nut, 3⁄8˝ 4 9⁄16˝ 30
Module mounting clip 4*
Module bolt, 1⁄4˝ 4* 7⁄16˝ 15
Flange nut, 1⁄4˝ 4* 7⁄16˝ 15
*Per module to be mounted. Series 5001 racks include clips and hardware to mount 2 to 6 modules.
Caution
Stainless steel hardware can seize up, a process
called galling.To significantly reduce the likelihood
of galling, apply a small drop of anti-seize lubricant
to the threads of all bolts before installation.
Anti-seize lubricants are readily available in auto
parts and hardware stores. In their absence, any
lubricant will reduce chances of galling.
Note: Parts are illustrated in exploded views (pp. 2–4).

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2
Installation Manual 524 Series 5001
Attach cross pipe
Assemble pole clamps to cross pipe
using 7/16-inch hardware. Finger
tighten initially, then torque to 30
foot-pounds before adding rails.
Mounting pole guidelines for UniRacs
The installer is solely responsible for use of the information below. These are general guidelines for normal installations. The
following variances can affect your installation:
• The required diameter and depth of the hole are dependent on soil type, which varies by locale. An installation in
loose, sandy soil will require larger, deeper holes and, therefore, more concrete than an installation in soil of average
density.
• The depth and width of the hole should also be increased in areas subject to winds in excess of 120 miles per hour,
particularly if the location of the mounting pole is open and unprotected. Design wind speed in the table below as-
sumes 29 psf wind force at 90 mph and 51 psf wind force at 120 mph, which correspond to Exposure Category C,
terrain that is flat and generally open extending one-half mile or more from the site in any quadrant. More severe
exposure—within a quarter mile of open water, for example—will require greater in-ground pole depth and concrete
volume.
• Poles taller than 6 feet above ground require that the depth of the hole be increased. Signifcantly taller poles may
require a larger pole diameter than called for in these installation instructions.
If in doubt, consult a professional civil engineer who is familiar with local soil conditions and wind load requirements.
1. Dig the hole at least four inches deeper than required under “In-ground pole depth” in the chart below. Fill the hole
with four inches of gravel to allow water drainage.
Design Maximum
Total area wind Hole In-ground Concrete above-ground
of modules speed diameter pole depth volume pole height
30 sq. ft. 90 mph 18 in. 45 in. 7 cu. ft. 6 ft.
30 sq. ft. 120 mph 24 in. 42 in. 11 cu. ft. 6 ft.
40 sq. ft. 90 mph 18 in. 54 in. 8 cu. ft. 6 ft.
40 sq. ft. 120 mph 24 in. 54 in. 14 cu. ft. 6 ft.
50 sq. ft. 90 mph 18 in. 56 in. 10 cu. ft. 6 ft.
50 sq. ft. 120 mph 24 in. 66 in. 17 cu. ft. 6 ft.
2. Stand the pipe in the hole. Brace the pole so that it is plumb. Pour concrete around the
pipe, filling the hole to ground level. Add an inch or two of extra concrete above the
hole. Use a trowel to form the concrete so that it slopes up to the pole (illustration).
3. Allow the concrete to set up for at least 24 hours before installing your UniRac.
Cross pipe
Lock washer
Pole
cap
Pole clamp
Schedule 40
3˝steel pole
(3
1/2˝O.D.)

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3
Installation Manual 524 Series 5001
Secure rails
Add rails, making sure that rails are parallel, equi-
distant from the center of the cross pipe, and tilt-
ing slightly. (This is not intended to be the final tilt
angle.) Tighten the U-bolt flange nuts enough to keep
the rails in place during module installation, when
the assembly will be temporarily out of balance.
Cross pipe
Saddle
SolarMount HD
(heavy-duty) rail
Rail cross section
A
Distance between rails’ outer edges (A) equals distance
between module mounting-hole centers minus 1 inch

Installation Manual 524 Series 5001
UniRac, Inc.
www.unirac.com
3201 University Boulevard SE, Suite 110
Albuquerque NM 87106-5635 USA
505.242.6411
505.242.6412 Fax
Page
4
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.
Install modules
Secure each PV module using two clips per rail. To
ensure a balanced array, center modules along the
rails. Initially finger tighten 1/4-inch flange nuts.
When all modules are in place, torque 1/4-inch flange
nuts to 15 foot-pounds.
Final adjustment
When the array is fully assembled, loosen the U-bolt flange
nuts enough to adjust the array’s tilt to the desired angle.
When satisfied, torque the flange nuts to 30 foot pounds.
The 7/16-inch nuts securing the pole clamps can be loosened,
allowing the entire array to turn on the pole. Be sure to re-
torque the nuts to 30 foot-pounds after final adjustment.
PV module
Rail (cross
section)
Module
mounting
clip