ASSEMBLY INSTRUCTIONS step-by-step - Lowes …

1 ASSEMBLYINSTRUCTIONSV ersion 2, Rev BPCN 062811-11 Top-of-Pole Mount for 6 Modules (TPM6)For Module Types E, F, G, & Hstep-by-stepassembly and installationE38-40 51-53 F38-42 58-62 G 37-42 61-67 H38-40 77-78 ModuleType WidthLengthA few words about the productAbout these ASSEMBLY InstructionsRequired ToolsFor foundation and pipe size recommendations on a specific installation, pleasecontact us at:Phone: 800-260-3792 Email: Are intended to be used by individuals with sufficient technical skills forthe task. Knowledge and use of hand tools, measuring devices and torquevalues is also various precautions in the forms of Notes, Cautions, andWarnings. These are to assist in the ASSEMBLY process and/or to drawattention to the fact that certain ASSEMBLY steps may be dangerous andcould cause serious personal injury and/or damage to the step -by- step procedures and these precautions shouldminimize the risk of any personal injury or damage to components whilemaking the installation not only safe but an efficient TPM6 for module types E, F, G & H is designed to mount on 6 inchSCH40/80 galvanized steel pipe (installer supplied).

2 Pipe size and foundation requirements are based on several factors including thearray surface area, maximum design wind speed, exposure category, soil type,steepest expected tilt angle, and above-ground general foundation and pipe size recommendations, please see our publicationtitled TPM Pipe and Foundation Recommendations .7/16 inch wrench or socket for 1/4 inch module hardware9/16 inch wrench or socket for 3/8 inch hardware3/4 inch wrench or socket for 1/2 inch hardware1-1/8 inch wrench or socket for 3/4 inch Pivot Bolt hardwareTorque wrenchRatchet wrenchRatchet extension bar3 to 6 foot levelTape MeasureSquareTop-of-Pole Mount for 6 Modules (TPM6) For Module Types E, F, G & HWARNING:Follow theprocedures andprecautions inthese of 10 ASSEMBLY INSTRUCTIONS , Top-of-Pole Mount for 6 Modules (TPM6) For Module Types E, F, G & H, (Version 2, Rev B)Top-of-PoleMount for 6 Modulesfor ModuleTypes E, F, G & H Parts Identification10111234567892 of 10 ASSEMBLY INSTRUCTIONS , Top-of-Pole Mount for 6 Modules (TPM6) For Module Types E, F, G & H, (Version 2, Rev B) step 1: Install the Mounting Sleeve on Vertical PipeStep 2.

3 Install the Strongback to the Mounting SleeveBefore installing the Mounting Sleeve, verify that the Mounting Pole is plumb tothe ground and hasn't shifted or leaned while the concrete footing has Mounting Sleeve slips on top of the Mounting Pole and has four 1/2 Set Boltswhich are used to secure it to the Mounting Pole. (See Figure 1-1)A. Slip the Mounting Sleeve on top of Mounting Pole and slide it down until itrests/bottoms out on top of Mounting Rotate the Mounting Sleeve so the Support Bar Pivot Tab is pointing northand the Strongback Vertical Towers are leaning Secure the Mounting Sleeve by tightening the four 1/2 Set Strongback is attached to the Mounting Sleeve using the Pivot Bolt that passesthrough its two Vertical Towers and the Support Bar. The Support Bar is attached tothe Strongback on one end and the Support Bar Pivot Tab of the Mounting Sleeveon the other end using 3/8 Remove the Support Bar from the Strongback and re-install in the 15elevation set point.

4 Secure with the 3/8 hardware and finger tighten. (SeeFigure 2-1)Torque eachSet Bolt to 55-60 Figure 1-1: Installing the Mounting SleeveFigure 2-1: Positioning Support BarCAUTION:Use care whileworking aroundthe structureduring could becomponents thatcreate hazards orobstruct freemovement causingserious bodilyinjury. Many are athead/eye slowly andwith care aroundthe work :This is a twoperson Strongbackmust be held inplace by oneperson while thesecond personaligns it andsecures it to theMounting Sleeveusing the PivotBolt and the 1/2 hardware. Failureto do so couldlead to seriouspersonal TowersLeaningSouthSupport BarPivot TabpointingNorthMountingPoleSet BoltsSet BoltsElevation Set PointsStrongbackSupportBar65 55 45 35 25 15 15 Position3 of 10 ASSEMBLY INSTRUCTIONS , Top-of-Pole Mount for 6 Modules (TPM6) For Module Types E, F, G & H, (Version 2, Rev B)B.

5 Remove the Pivot Bolt from the Mounting Sleeve and also collect the 3/8 x1-3/4 bolt, flat washers and lock washer needed to secure the Support Barto its Pivot Tab on the Mounting Sleeve. (See Figure 2-2)C. Orient the Strongback to the Mounting Sleeve with its Lower Support Barpositioned on the same side of the Mounting Sleeve as the Support Bar Pivot Slide the Strongback between the two vertical mounting tabs, aligning thethru-hole of the Strongback with the holes of the two Vertical Insert the Pivot Bolt along with one flat washer through the one VerticalTower and the Strongback exiting the second Vertical Tower on the oppositeside. Secure with the remaining flat washer, lock washer and hex nut. Fornow, finger tighten only to allow movement for the next 2-2: Installing the StrongbackNOTE:Although thissystem offers sixelevation setpoints, for ease ofassembly, set theangle to its lowestsetting tilt settingof the rack will takeplace later in of 10 StrongbackBolt3/4 x 5-1/2 PivotFlatWasherVertical TowersFlatWasherLock Washer3/4 Hex NutMountingSleeveAssembly INSTRUCTIONS , Top-of-Pole Mount for 6 Modules (TPM6) For Module Types E, F, G & H, (Version 2, Rev B)F.

6 Pivot the Strongback and the Support Bar to align the mounting holes of theSupport Bar with its Pivot Tab on the Mounting Sleeve. Slide the SupportBar over the Pivot Tab. Insert the 3/8 x 1-3/4 bolt and one flat washerthrough the Support Bar and Mounting Tab and secure it with the remainingflat washer, lock washer and hex nut.(See Figure 2-3)G. Return and tightenCross-Bars run in an E-W direction and are secured to the mounting angles (using 3/8 square flat washers along with 3/8 x 3-1/4 bolts andhardware. There are two Cross-bars to install, at opposite ends of the are mounted to the outside of the Strongback mounting angles (these arewelded to the Strongback); they are not nested into the Mounting Angles. (See Figure 3-1)A. Position the Cross-Bar to the outside of themounting angle (seeFigure 3-1). Align the mounting holes and secure using 3/8 flat and squarewashers along with the 3/8 x 3-1/4 bolts and lock washer placing thesquare flat washer against the Cross-Bar.)

7 Tighten hardware and(See Figure 3-2)B. Continue in this manner and install the opposite Cross-Bar to theStrongback. Refer to Figure 3-1 as needed for proper hardware on both ends ofSupport Bar at 32-34 to 125-150 to30-32 Pivot Bolt,weldedto the Strongback)StrongbackStep 3: Install the Cross-Bars to the StrongbackInstalling the x 1-3/4 Flat WasherPivot TabFlat WasherLock WasherSupport Bar3/8 Hex NutFigure 2-3: Securing Support Bar to Mounting SleeveCAUTION:This is a twoperson arelong and unstablebefore they arefully secured to theStrongback. Cross-Bars must be heldin place by oneperson while thesecond personaligns and securesthem to theStrongback. Failureto do so could leadto serious of 10 ASSEMBLY INSTRUCTIONS , Top-of-Pole Mount for 6 Modules (TPM6) For Module Types E, F, G & H, (Version 2, Rev B)StrongbackCross-BarMountingAngleCORREC TWRONGF igure 3-1: Cross-Bar Positioning relative to Mounting Angles6 of 10 Figure 3-2: Installing Cross-Bars on the StrongbackStrongbackCross-Bar3/8 SquareWasherFlat WasherFlat WasherLock Washer3/8 Nut3/8 x 3-1/4 BoltWARNING:Be sure to placethe 3/8 squarewashers on thesurface of theCross-Bar and notthe MountingAngles of to do sowill damage thesurface of theCross-Bar whenthe attachinghardware INSTRUCTIONS , Top-of-Pole Mount for 6 Modules (TPM6) For Module Types E, F, G & H, (Version 2, Rev B) step 4.

8 Install the Module Rails to the Cross-BarsModule Rails run in an N-S direction and are secured to the mounting tabs of theCross-Bars (these are welded to the Cross-Bars) using 3/8 x 1 bolts and are four Rails to Rails are installed differently depending on whether they are mountedinboard or outboard of the Cross-Bars. (See Figure 4-1)A. Referring to Figure 4-1, for orientation of the Module Rails, position andalign the Module Rail mounting holes with the holes of the Cross-Barmounting tabs and secure with 3/8 x 1 bolts and hardware. Finger-tightenfor now. (See Figure 4-2)Start by installing the inboard sections of Module Rail first and work of 10 Cross-BarModuleRail (in)RedView looking NorthCross-BarMounting TabFigure 4-1: Orientation of Module Rails to Cross-BarsNOTE:Finger-tighten theModule Rails tothe Cross-Barswhile all ModuleRails are installed,re-tighten tospecified.

9 This is a twoperson Rails areunstable beforethey are fullysecured to Rails mustbe held in placeby one personwhile the secondperson aligns andsecures them tothe to do socould lead toserious INSTRUCTIONS , Top-of-Pole Mount for 6 Modules (TPM6) For Module Types E, F, G & H, (Version 2, Rev B)Next, install the outboard sections of Module Referring to Figure 4-1 for orientation of the outboard Module Rails,position and align the Module Rail mounting holes with the holes of theCross-Bar mounting tabs and secure with 3/8 x 1 bolts and for now. (See Figure 4-3)Module RailCross-BarStrongback3/8 x 1 BoltLock WasherFlat WasherFlat Washer3/8 NutNEWSF igure 4-2: Installing the Inboard Module Rails to Cross-Bars8 of 10 NOTE:Double check theorientation ofinboard tooutboard ModuleRails. If they areinstalled differentlyfrom theseinstructions themounting holeswill not align to theholes of the RailCross-BarStrongback3/8 x 1 BoltLock WasherFlat WasherFlat Washer3/8 NutNEWSF igure 4-3: Installing the Outboard Module Rails to Cross-BarsAssembly INSTRUCTIONS , Top-of-Pole Mount for 6 Modules (TPM6) For Module Types E, F, G & H, (Version 2, Rev B) step 5: Installing PV Modules to Module RailsStep 6: Now return and tighten mounting hardwareStep 7: Adjust the Tilt Angle of the RackPV Modules are secured to the Module Rails using 1/4 x 3/4 bolts and with the southern most PV Modules and work in a northern direction.

10 Thisprovides a measure of safety as the previously installed southern Modules can helpto hold the next in-line northern Module in place during installation. (See Figure 5-1)A. Place the southern most PV Module in place on the Module Rails. Align themounting holes and secure with 1/4 x 3/4 bolts and hardware. EachModule has four attachment points. Finger-tighten for Continue in this manner to install all southern most PV Modules first andthen work in a northern direction installing the remaining Return and tighten each set of the 3/8 mounting hardware, securing theModule Rails to the Return and tighten each set of 1/4 mounting hardware, securing the PVModules to the Module adjust the tilt angle, loosen the Pivot Bolt hardware and removing the SupportArm upper hardware attaching the Support Arm to the Strongback. Use great care inthis procedure as it can be dangerous if the procedure is not completed as describedwith a minimum of two While one person holds the south edge of rack, the other loosens the PivotBolt and removes the upper 3/8 hardware attaching the Support Bar to theStrongback.