TM
Our Company
Orion Solar Racking specializes in Engineering, designing, development and Manufacturing of PV Mounting
solutions. Since its foundation Orion has released a wide range of quality and innovative mounting systems.
We provide roof mount; ground mount; Pole mount; single axis trackers; car-ports for Commercial,
agriculture, industrial, government & educational as well as utility grade projects. Each and every day
we endeavor to make simple yet innovative solar racking solution, Orion provides LIVE technical
support for all of distributors, dealers and contractors.
Here at OSR You can trust our knowledge of installation, code compliance and necessary technical
documentation to always be above the rest.
Online tools like our On-line calculator, installation videos and our In-House
Research & Design teams are eager to help you solve your toughest Construction challenges.
We now play a leading role in the solar industry and have a rapidly gained recognition amongst
system integrators, installers and distributors across the world..
Mission Statement
Our mission has always been to provide quality products and promote green renewable energy
Solutions, that reduce our dependency on earth depleting methods that may contaminate our
environment
-Over 80% pre-assembled
-Adjustable from 10-60 degrees of tilt
-Simple yet innovative design
-Compatible with most roofing materials
-Commercial & residential solution
-Code compliant
(**Bolts, Washers, nuts and Legs all are set-in place)
C
US
Mars Series
Adjustable Tilt-Angle
TM
Handling & Installing Orion Solar Racking
It is critically important to observe standard safety practices when installing Orion Solar Racking:
Stop work during stormy weather. Solar modules can be blown in high winds
Never step or sit on the glass surface of a solar module. The glass may break, resulting in shock
or bodily injury
Do not throw or roughly handle any Orion Solar Racking components
Do not bring Orion Solar Racking into contact with sharp or heavy objects
Do not modify Orion Solar Racking components in any way. The exchange of bolts, drilling of
holes, bending and any other physical changes not intended in standard installation procedure
will void the warranty
Products should be installed and maintained by qualified personnel. Keep unauthorized personnel
away from solar modules
It is the installer’s responsibility to verify the integrity of the structure to which Orion Solar
Racking is fixed. Roofs or structures with rotten/rusted bearers, undersized bearers, excessively
spaced bearers or any other unsuitable substructure cannot be used with Orion Solar Racking
Installation on such structures could result in death or serious injury and will void the warranty
Rail Calculation & Design
Rail Calculations based on code approved stress equations, and allowable margins of safety.
Beam calculations have been conservatively performed under wind loads, snow, dead loads
Components have had full envelope forces applied to each components from the standard tables.
for more detailed information regarding our products and site specific data please visit our Website
www.OrionRacking.com or give our customer service department a call to assist you with any
documentation that might be necessary for submittal, or building permit applications.
Features
Aluminum 6005-T5 extrusion
Suitable for buildings up to 30’ in height
Suitable for roof slope range from 0° to 65°
Static load capacity from 20 N to 1800 N
Significantly higher strength-to-weight ratio than other framing products
System comes 75% pre-assembled, saving time and labor cost
System is fully adjustable from 5 Degrees of tilt to 60 Degrees
Complies with ASCE 7-05 guidance for wind load design
Before Installing
CAUTION Installation team must read this Installation manual
before attempting installation. Failure to correctly
establish the requirements of the proposed installation site is
dangerous and can also void the framing & Roofing warranty.
1
18
Index
Tools
Handling & installation
1
Rail Calculation
1
Features
1
Tools
2
Component List
3
Component List Continued
4
Module Planning & Assembly
5
System Layout
6
Rail Attachment
7
Integrated Grounding/End Clamp
8
Integrated Grounding Details
9
Integrated Grounding/Mid Clamp
10
Splicing Detail
11
SPlicing Kit
12
Front Leg Mounting
13
Rear Leg Mounting
14
Adjustable Legs
15
Span Chart
16
Index
17
17
6mm & 8mm Metric Allen Key/
6mm & 8mm Hexagonal Driver Bit
Chalk line Reel
Construction Hard Hat
Construction Gloves
Measuring Tape
Safety Harness
Drill w/ 7/32 bit
2
Component List
Span Chart
Rail
Mid Clamp
Clear&Black Anodized
OSR-R
Clear&Black Anodized
OSR-MC-
Orion Solar Racking: EXP. B*
Splice Bar
Ground Lug
Clear&Black Anodized
OSR-SPL-B
OSR-G-MGL
Universal End Clamp
End Clamp
Clear&Black Anodized
OSR-EC-UNV
Clear&Black Anodized
OSR-EC
Grip Mid Clamp
Grip End Clamp
(optional)
OSR-GMC
(optional)
OSR-GEC
3
Orion Solar Racking: EXP. C*
16
Adjustable legs
Component List (Continued)
Adjustable Rear Legs **
Front Adjustable Leg
OSR-AT-FL
30 To 60 Degree
OSR-AT-RL3060
1.
10 To 15 Degree
OSR-AT-RL1015
15 To 30 Degree
OSR-At-RL1530
Grounding Clip
OSR-G-WEEB-OCR
30 To 60 Degree
OSR-AT-RL3060
15 To 30 Degree
OSR-AT-RL1530
2.
** Please note that we provide 3
different types of adjustable
legs. Please see page 11
Bonding Jumper
OSR-G-BJ
10 To 15 Degree
OSR-AT-RL1015
3.
Both WEEB clips and bonding jumper are used
to create an electrical connection between two pieces
of anodized aluminum which have been mechanically spliced
15
4
Planning Your Module Layout and Assembly
Rear Leg Module Mounting
25%
Recommended
Span**
25%
Inter row spacing will vary depending upon the Tilt
angle of the array
Rear leg can be adjusted to
desired height to achieve
correct tilt angle
Rails must be set inside
(as shown above)
** Must follow PV Module
manufactures
recommended span
between Clamp attachment
End Clamp Installation
Mid Clamp
Universal
End-Clamp
When calculating rail lengths add 1/2” inch per Mid-clamp and 2
1/2 “ inches per End-clamp.
Maximum rail span between Rafters, standoff’s or attachment
points with Orion standard rail is 4Ft to 6ft. if using Orion HD
Rail, installer can span up to 8ft between Rafters, standoff’s
or attachment points.
Tilt in channel nut
5
Set channel nut
Tighten Channel nut
14
Complete
Front Leg Module Mounting
Orion Mars Adjustable System Layout
Find rafter or truss spacing, most
common rafter or truss spans found are:
16” O.C. to 24” O.C.
Mark the center of rafters and begin
pre-drill pilot hole for the lag bolts,
pilot holes must not exit the bottom of
the rafter or truss.
Set both legs to desired Tilt
angle, by using an angle finder,
straight edge or a string-line
level
Truss
Spanner
Tilt-in End clamp to front leg
and fasten to PV Module and
then proceed to install
Mid-clamp and the next PV
module keeping all edges
A spanner can also be installed to
provide an attachment point if truss or
rafter cannot be found or is not suitable
for installation.
Orion Mars Adjustable L-Foot Installation
End Clamp Installation
Tilt in channel nut
Set channel nut
Tighten Channel nut
13
Complete
6
Rail Attachment
Rail Splice Kit
Rear leg assembly
ge
t
gh
tr
Ed
Use splice bars when expanding
rail length
ai
S
To splice Rails start by inserting splice
bar kit into side channel
Attach rails to front and
rear legs
Once rails are in place and
fastened, installer can use
a straight edge, PV module
or piece of surplus rail to
set a uniform tilt angle on
both
front and rear legs
Tighten M8 Set-screws to 12 ft-lbs
nominal torque
Front leg assembly
(As shown above)
Splice Bar
Front View
Rail
Rail Side View
Rear Leg Adjustment
Side View
1.
Tilt in rail on side channel
Front View
2.
3.
Set channel nut
7
Once leg is adjusted
to desired height set
screw should be
tightened and hex nut
should also be
tightened to lock
set-screw in place
Tighten channel Nut bolt
12
Orion Integrated Grounding w/End
Splicing Detail
Front View
DETAIL VIEW
SPLICING
C
A
B
ROUND MID CLAMP
OSR-RAIL
Step 1: Insert the Grip End Clamps, each consisting of (2)
caps, (1) lock washer, (1) serrated washer, (1) hex bolt, and (1)
channel nut into the rail (do not tighten the hex bolt, but
provide 2 turns to ensure that the bolt stay in place
Step 2: Set the PV panel at the end of the row in place, and
Insert the end spacer (do not tighten the hex bolt of the grip
end clamp.)
A
OSR-RAIL
C
B
PBO-BST
BALLASTED STRAP
WEIGHT TRAY
11
DETAIL VIEW
OF SPLICING
Step 3: Tighten the hex bolt using 7/16” socket to 14.6 ft. lbs.
Torque. (end spacers are available to match the correct PV
frame thickness)
8
Orion Integrated Grounding w/Mid
Integrated Grounding/Mid Grip Details
Front View
A
B
C
Step 1: Insert the Grip Mid Clamps , each consisting of (1) cap, (1)
lock washer, (1) serrated washer, (1) hex bolt, and (1) channel nut
into the Rail that is holding an existing PV panel. (do not tighten the
hex bolt, but provide 2 turns to ensure that the bolt stay in place)
A
Step 2: Set the PV panel parallel to the existing PV panel with the 2
grip mid clamps in between. (do not tighten the hex bolt of the grip mid
clamp.)
6-10 AWG WIRE
BARE COPPER
GROUNDING WIRE
OSR-SGC - GROUNDING CLIP
BONDS THE GROUND WIRE
TO THE RAIL/END MODULE
OSR-GEC -END CLAMP
C
B
Step 3: Tighten the hex bolt using 7/16” socket to 14.6 ft. lbs.
Torque.
SOLAR MODULE
OSR-R-STD - ORION RAIL
OSR-GMC - MID CLAMP
MODULE TO MODULE BONDING
9
10