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Our Company
Orion provides live technical customer support. At OSR You can trust our knowledge of installation, code
compliance and necessary technical documentation. Online tools like our On-line calculator, installation videos
and our in-house design team are available to help you solve your toughest construction challenges.
Mission Statement
Our mission is to provide quality products that promote green renewable energy solutions, that reduce our
dependency on earth depleting methods that contaminate our environment.
SolarStap Technology (Patent Pending)
The patent pending SolarStrap technology is breakthrough design offering a complete solution to zero
penetration lightweight pv installation. The technology was invented by Jonathan Port, CEO of PermaCity
Corporation, a U.S. leading Engineering Procurement Contractor with more than 30 MWs installed and
operating in the United States. The SolarStrap features patented Z Bracket” technology used by PermaCity to
build more than 30 Costco locations. These combined technologies solve the needs of the modern solar roof –
zero exposed penetrations, no ballast required, suitable for anything from one solar panel up to the largest
systems, fast, inexpensive, and easy to install. PermaCity is deploying the SolarStrap on the largest solar roof in
California, 5.2 MWs on the headquarter of Forever 21 in Los Angeles.
Patent Pending
-
One Tool Fast and Easy Installation
Integrated Code Compliant Grounding
No Exposed Roof Penetrations
High Wind and Earthquake Resistance
Wind Tunnel Tested and SEAOC Compliant
Code Compliant
C
US
Orion Solar Strap
Solar Racking
Orion Solar Racking (OSR) 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 manufacture simple yet innovative solar racking solutions.
Handling & Installing Orion Solar Racking
Wire Management and Grounding
It is critically important to observe standard safety practices when installing Orion Solar Racking:
Follow all OSHA safety guidelines for construction safety
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 used. 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
Pv Wire crossing
(optional)
Conduit home runs to inverter
can hang on bracket
(front and back)
Span Calculation & Design
Span and roof loading 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 component from the standard tables.
for more detailed information regarding our products and site specific data please visit our Website
www.OrionRacking.com/solarstrap 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 5052 - 6061
Suitable for all buildings
Suitable for roof slope range from 0° to 20°
Panel array weight under 3lbs/square foot
Higher strength-to-weight ratio
Spacing efficiency with integrated setback adjustments
High corrosion resistance materials resulting in low lifetime
maintenance and an extended product life
Complies with ASCE 7-05 and ASCE 7-10 guidance for wind load design
Complies with SEAOC PV-1 and PV-2 wid design for low-profile solar photovoltaic arrays.
Ballast only option under 5lbs/square foot in most Western U.S. locations.
Tested to 120 MPH wind zones.
Before Installing
CAUTION:
Installer must read this manual before attempting installation.
Failure to correctly establish the requirements of the proposed installation
site is dangerous and can void the framing or roofing warranty.
1
Grounding Lay Lugs
attached to wing of
high bracket
For wire management use EMT or Schedule 80
PVC conduit supported by a one-hole strap and
one self tapping screw to attach your conduit to
either side of the wing. Use plastic end
protection if using EMT. EMT should be avoided
for inter row crossings if the local AHJ
requires bonding of EMT at these locations.
14
Tools
Drill w/ impact driver
Chalk line Reel
Construction Hard Hat
Construction Gloves
Measuring Tape
Safety Harness
Safety glasses
13
2
Component List
Solar Strap™
Universal Connect Strap
PBO-SS
PBO-UCS
**Pan Strap PBO-PS(Optional)
Low Bracket
High Bracket
PBO-LB
Available in 5˚, 10˚, & 15˚
PBO-HB
Available in 5˚, 10˚, & 15˚
Grip Mid Clamp
Grip End Clamp
OSR-GMC
OSR-GEC
SGB5 Ground Lug
Kep Nut
OSR-G-GL
3
12
Index
Exploded View
Design & Spam
1
Features
1
Handling
1
Tools
2
Component List
3
Exploded View
4
Planning & Layout
5
System Layout
6
Strap Lay-down
7
Add Brackets
8
Front/Side Views
8
Mid Clamp Installation
9
Complete Installation
9
End Clamp Installation
10
Index
11
Wire Management & Grounding
14
Solar Module
End/mid Clamp
High Bracket
Low Bracket
Universal
Connect Strap
Solar Strap™
**Pan Strap
Option
11
4
Planning and Layout of Solar Strap
End Clamp/Integrated ground installation
Front View
Spans for
inter-row
spacing vary
between different
module tilt
angles
y1
y2
y2
y2
y2
Identify set point on
universal connect
strap (y²)
y1
x
x
x
y¹ = module width
y² = universal connect
strap set point
Please note that AHJ may request seismic attachment
for certain zones. Please verify with your local city
ordnance.
Step 1: Insert the Grip End Clamps, each consisting of (2)
caps, (1) lock washer, (1) serrated washer, and (1) hex bolt,
into the 1/4” dia. attachment hole in both high and low brackets at the end of the row. (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.)
Modules should be mounted in Landscape
orientation unless otherwise specified on the plans.
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)
5
10
Complete Installation
Solar Strap System Layout
Chalk Line
Snap horizontal and vertical
lines or chalk-mark the position
of each assembly support
bracket for a quick & easy
layout
Grounding Lay Lugs
attached to wing of
high bracket
**Pan Strap
w/ballast block
(Optional)
Mid Clamp/integrated ground Installation
It is recommended that the
Installer follow final
design layout
Front View
Step 1: Insert the Grip Mid Clamps , each consisting of (1) cap, (1)
lock washer, (1) serrated washer, and (1) hex bolt, into the 1/4” dia.
attachment hole in both high and low brackets that are holding an
existing PV panel. (do not tighten the hex bolt, but provide 2 turns to
ensure that the bolt stay in place)
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.)
Step 3: Tighten the hex bolt using 7/16” socket to 14.6 ft. lbs.
Torque.
Installer must follow all OSHA CFR1926
rules & regulations regarding Job-site
safety, fall protection and PPE for
more info visit:
9
Installer must verify
that all city, Fire Dept.
or jurisdictions for
Residential or
Commercial roofs are
Installer must verify that PV
Module manufacturers
attachment points for clamps
are met to avoid damage,
injuries and module warranty
being void
www.osha.gov
6
Lay Down Straps
Add brackets
1.
2.
High
Bracket
Low
Bracket
**Pan Strap Option
w/ballast block
Side View
**Pan Strap Option
w/ballast block
Pan Strap
Side View
1) Strap or pan Strap
2) Universal Connector Strap
Make sure Low bracket is facing towards the sun. South, East, or
West not North
Front View
Low Bracket
7
High Bracket
8