ASSEMBLY INSTRUCTIONS RESIDENTIAL SOLUTION

CROSSRAIL GROUND MOUNT SYSTEM

USA

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TABLE OF CONTENTS

SAFETY REGULATIONS

MATERIALS REQUIRED

ASSEMBLY

ENGINEERING DRAWINGS

TERMS AND CONDITIONS

TABLE OF CONTENTS

ENGINEERING STRENGTH IS AT OUR CORE

With sophisticated product innovations and a deep customer focus, Everest Solar is the engineering leader for all your mounting system needs. We are the US division of K2 Systems, one of Europe’s market leaders with more than 3.0 GW installed.

We offer proven product solutions and innovative designs. Wind tunnel testing along with advanced structural and electrical validation to facilitate permitting, design and installation. Our designs result in cost competitive racking systems with dedicated support that will position you to win more projects.

We partner with our customers and suppliers for the long-term. High quality materials and cutting edge designs provide a durable, yet functional system. Our product line is comprised of a few, coordinated components that lower the cost of materials, and simplify installation, saving you time and money. All backed by German engineering, a long track record of quality and a company that is here to stay.

Thank you for choosing Everest Solar Systems for your Solar PV Project.

2 | 14 Table of Contents

GENERAL SAFETY INSTRUCTIONS

Everest Solar Systems’ General Assembly Instructions must be followed to maintain the exclusive, limited product warranty.You can access these instructions at Everest Technical Info Pagehttp://www.everest-solarsystems.com/us/downloads/technical-information.html or by contacting us directly.

In general, the following applies:

¬ Systems should be installed by experienced contractors licensed and qualified to perform the work with professional workmanship and quality.

¬ Before installation, Contractor must verify that the system meets all applicable laws, regulations, ordinances, and codes. Contractor shall verify that the roof or other structures to which the system is being attached are capable of carrying the system loads. For information about the dead loads of the various system components, Contractor should review the Everest Technical information page at http://www.everest-solarsystems.com/us/downloads/technical-information.html or contact us directly.

¬ Contractor is solely responsible for work safety and accident prevention regulations and corresponding standards and regulations of the applicable occupational safety and health agency are followed, including:

- Safety clothing is worn such as safety helmets, work shoes, and gloves. - Where required, the contractor should use fall protection, scaffolding with arrestor equipment and other approved methods

for worker safety.

¬ Contractor shall verify that it is using the most current instructions by downloading the latest version from our website or contacting our office directly.

¬ Module manufacturer installation guides must be followed. Please use approved electrical bonding and grounding components that are required by the local or national codes and AHJ.

¬ A copy of these instructions must be on site, and read and understood by all workers during installation.

¬ In the event our general installation and assembly instructions are not followed, or that not all system components and assemblies are used according to these instructions, or that components are used which were not obtained from us, Everest Solar Systems is not liable for any resulting defects and damages, and the exclusive, limited warranty will be void.

¬ The exclusive, limited product warranty shall apply only if all instructions are strictly adhered to and the system is correctly installed. Everest Solar Systems disclaims any and all warranties, express or implied, including without limitation any warranties of merchantability and fitness for a particular purpose other than as set forth in the exclusive, limited warranty in the terms and conditions of sale, which can be viewed under on our website: http://www.everest-solarsystems.com/us/downloads/technical-information.html

¬ The dismantling of the system should be in reverse order of these assembly instructions.

3 | 14Safety Regulations

CrossRail for Ground Mount:¬ Pre-engineered System:

- 4 rows in landscape- 20-35° tilt- 0-50 lbs Snow, 100-130 mph Wind - Low part count

¬ Uses the Everest CrossRail 80 & L-Bracket kit on standard 1.5 - 2.0“ pipe & Hollaender connectors

¬ Low cost system with easy installation

CrossRail 80

Material: aluminumFinish: mill, dark anodizedStandard length: 164“, custom

Bonding End Clamp Set

Material: stainless steelFinish: silver, dark

Bonding Mid Clamp Set

Material: stainless steelFinish: silver, dark

Module End Clamp Set

Material: aluminumFinish: mill, dark anodizedHardware: stainless steel

Module Mid Clamp Set

Material: aluminumFinish: mill, dark anodizedHardware: stainless steel

M10 Serrated Flange Nut and

T-Bolt 28/15 M10

Material: stainless steel

Hollaender No. 70 External CouplingMaterial: aluminum

Hollaender 17E Adj. Elbow

OR

Tee-E Assembly + Hollaender 17 Adjustable Elbow or Tee Assembly

OR

Hollaender 17x-9 Adjustable Elbow or Tee Assembly

Material: aluminum

Hollaender 5 EXT Extended Barrel Tee OR

Hollaender 5 EXMaterial: aluminum

Everest Pipe L Bracket Kit

Material: stainless steel, galvanized steel

4 | 14Materials Required

Optional: End Cap for CrossRail 80

Material: glass fiber reinforced polyamide

Optional: External Omega Cable

Clip

Material: polyamide, black

TORQUE SPECIFICATIONS¬ M10 T-Bolts: 25.8 lb-ft (35 Nm)

¬ M8 T-Bolts: 10 lb-ft (13.5 Nm)

¬ M8 Allen Bolts: 10.3 lb-ft (14 Nm)

TOOLS REQUIRED¬ Torque wrench (0 – 50 lb-ft)

¬ Cordless Drill (non-impact)

¬ 13mm Deep Socket

¬ 15mm Deep Socket

¬ Measuring Tape

¬ Excavation Equipment

¬ 3/8“ Hex Head Wrench

¬ Hollaender Set Screw

¬ SW6 Hex Drive

Optional: HEYClip SunRunner Cable

Clip SS, S6404

Material: stainless steel

TOOLS AND TORQUE SPECIFICATIONS REQUIRED Everest Solar Systems are designed to make installation easy and fast. The basic tools required to assemble the parts are listed below as a guide.

Tools and materials for the installation of third party items or items used for bonding and grounding are not listed here. Please refer to the instructions of those third party products.

5 | 14Materials and Tools Required

LOCATE FOOTINGS

CUT GALVANIZED PIPE

Locate and excavate footings per spacing requirements shown on layout plan (sheet S100), layout elevation (sheet S101), and installation schedule (sheet S102).

Materials required: Tape measure, string line, drill.

Cut galvanized pipe, including vertical posts and horizontal beams, to required lengths. Drill holes and place rebar in pipe as shown on elevation (sheet S101).

¬ Slide Hollaender aluminum tees (#5EXT-8, #5EX-8, #5EX-9), elbows (#17E, #17), and couplers (#70) if required on to horizontal pipe lengths.

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Use stakes or an alternative temporary shoring method to place horizontal galvanized pipe at the elevations required to achieve specified tilt (see sheet S101, sheet S102).

¬ Slide Hollaender aluminum tees (#5EXT-8, #5EX-8, #5EX-9) and elbows (#17E, #17) and tighten set screw enough to prevent fittings from sliding.

Connect vertical posts to horizontal pipe using appropriate tee fitting and use Hollaender tool or hex drive to tighten bottom set screw to required torque value (sheet S103).

At this point, the vertical post pipe should still be able to rotate freely around the horizontal pipe.

ASSEMBLE MAIN PIPE STRUCTURE IN PLACE: HORIZONTAL PIPE

ASSEMBLE MAIN PIPE STRUCTURE IN PLACE: VERTICAL PIPE

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ASSEMBLE MAIN PIPE STRUCTURE IN PLACE: BRACINGAttach all side bracing tubing into place. Do not torque to specified rating yet.

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6 | 14Installation of CrossRail Ground Mount System

ASSEMBLY: STEP BY STEP

7 | 14Installation of CrossRail Ground Mount System

PLACE L-BRACKET ASSEMBLYAttach U-Bolt to L-Bracket around horizontal pipe using hex nuts as shown on detail B (sheet S104).

Attach L-Bracket to CrossRail 80 using M10 T-Bolts and M10 Serrated Flange Nut (sheet S104).

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ATTACH RAIL TO BRACKET

Set CrossRail 80 on to horizontal galvanized pipe at spacing required to support PV modules per the panels’ manufacturer guidelines.

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POUR CONCRETE IN PLACE

Ensure vertical pipe posts are plumb and located in foundation excavations per the spacing requirements shown in the layout plan, layout elevation, and installation schedule (sheets S100, S101, and S102).

Pour or pump mixed concrete into excavated footings and allow time for curing.

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FINAL ASSEMBLY AND MISCELLANEOUS COMPONENTS

Remove temporary shoring and, if required, install piping for Tie-Brace (sheets S100, S101 and S103) and V-Brace (sheets S100, S101 and S105) as outlined in the installation schedule (sheet S102).

Tighten all set-screws as shown on the detail sheets (sheets S103, S104). Adjust CrossRail 80 to final location as required to support PV modules.

Tighten U-Bolt hex nuts to torque requirements shown on sheet S104. Ensure M10x lock nuts are tightened to specified torque.

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INSTALL SOLAR PV MODULESInstall solar PV modules per the steps outlined in the CrossRail Assembly Instructions (separate document):http://www.everest-solarsystems.com/us/downloads/technical-information.html

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G Wind Speed* Snow* Tie-Brace A A1

TILT

ANGLE

ASCE 7-05 /

7-10 (mph)

Ground Snow

LoadRequired? Pipe Size

Pipe

SpecifcationPost Spacing

Post Spacing

w/ V-BraceFront Back Front Back

Yes Sch. 40 7'-9" 11'-9" 2'-0" 4'-0" 2'-4" 5'-0"

Yes Sch. 80 8'-9" 13'-6" 2'-0" 4'-0" 2'-4" 5'-0"

Yes Sch. 40 9'-9" 15'-0" 2'-0" 4'-0" 2'-3" 5'-0"

Yes Sch. 80 10'-9" 16'-0" 2'-0" 4'-3" 2'-9" 5'-3"

Yes Sch. 40 5'-6" 9'-0" 2'-0" 4'-4" 3'-0" 6'-0"

Yes Sch. 80 6'-3" 10'-9" 3'-0" 5'-0" 3'-0" 6'-0"

Yes Sch. 40 7'-6" 12'-0" 2'-3" 5'-4" 3'-3" 7'-0"

Yes Sch. 80 9'-0" 13'-6" 2'-6" 6'-0" 3'-9" 7'-0"

Yes Sch. 40 5'-3" 9'-0" 2'-3" 5'-0" 3'-3" 6'-0"

Yes Sch. 80 5'-9" 9'-9" 2'-3" 5'-0" 3'-3" 6'-0"

Yes Sch. 40 7'-0" 11'-0" 2'-3" 5'-0" 3'-4" 6'-4"

Yes Sch. 80 8'-0" 10'-6" 2'-4" 5'-3" 3'-9" 7'-0"

Yes Sch. 40 5'-6" 8'-3" 3'-0" 6'-0" 3'-6" 7'-3"

Yes Sch. 80 5'-9" 8'-3" 3'-0" 6'-0" 3'-6" 7'-3"

Yes Sch. 40 7'-0" 9'-0" 3'-0" 6'-6" 3'-4" 7'-6"

Yes Sch. 80 8'-0" 10'-6" 3'-0" 7'-0" 3'-6" 8'-0"

Yes Sch. 40 4'-6" 6'-3" 3'-0" 6'-0" 3'-3" 6'-6"

Yes Sch. 80 5'-6" 7'-3" 3'-0" 6'-0" 3'-3" 7'-0"

Yes Sch. 40 6'-0" 8'-9" 3'-0" 6'-0" 3'-4" 7'-4"

Yes Sch. 80 7'-0" 11'-0" 3'-0" 6'-6" 4'-8" 8'-3"

1.5"

2"

30˚-35˚ 105 / 130 50 psf

30˚-35˚ 105 / 130 30 psf

1.5"

2"

INSTALLATION DIMENSIONS

20˚ 85 / 100 0 psf

Pipe Data

2"

1.5"

CONCRETE DEPTH (A)

30 psf90 / 10530˚-35˚

30˚-35˚ 90 / 105 50 psf

CONCRETE DEPTH (A1)

1.5"

2"

1.5"

2"

CrossRail Ground Mount Assembly Instructions US5 - 0416Product images are for illustrative purposes only. Specifi cations aresubject to change without notice. All sales of our products shall besubject to Everest Solar Systems terms and conditions, includingthe exclusive limited warranty set forth therein.

K2 Systems International: World headquarters K2 Systems GmbH, GermanyK2 Systems SARL, FranceK2 Systems SRL, ItalyK2 Solar Mounting Solutions Ltd., UK

Everest Solar Systems, LLC3809 Ocean Ranch Blvd.Suite 111Oceanside, CA 92056Tel. +1.760.301.5300info@everest-solarsystems.comwww.everest-solarsystems.com

TERMS AND CONDITIONS

Product images are for illustrative purposes only. Specifications are subject to change without notice. All sales of our products shall be subject to Everest Solar Systems terms and conditions, including the exclusive limited warranty set forth therein. The terms and conditions can be found at http://www.everest-solarsystems.com/us/downloads/technical-information.html

THANK YOU FOR CHOOSING AN EVEREST SOLAR SYSTEMS MOUNTING SYSTEM.Systems from Everest Solar Systems are fast and simple to install. Please contact us if you have any questions or suggestions for improvements. We are looking forward to receive your call on our

Service-Hotline +1 760.301.5300

Ready!