FR510-6 Installation Manual

Introduction & Product Profile

Sollega designs, tests, and manufactures solar mounting solutions, injection-molding its racking in Baldwin Park, California. The FastRack (FR510-6) is a patented, one-piece, injection-molded solar racking system designed for both commercial low-pitch (<7°) roofs and ballasted ground-mount installations. It is molded from glass-filled Nylon for strength and durability in a lightweight 4.6 lb part, carries a 25-year warranty, and is 100% recyclable (#7 Other).

The FR510-6 is compatible with most common solar panels on the market. Its universal design enables module installation in landscape orientation, and all attachments are top-down using one size tool (1/2" socket) for easy installation. The one-piece bucket arrives ready to install, requiring no assembly, and is efficient to ship, stage, and install.

Receiving & Inspection

Pallets ship on a bespoke pallet and arrive shrink wrapped for protection. FastRacks arrive in stacks of 90 with hardware pre-installed.

Getting Started — Required Tools

• 3/8" socket wrench & 1/2" socket
• 1/4" calibrated torque wrench (20–240 in-lbs)
• 3/8" calibrated torque wrench (5–100 ft-lbs)
• 1/4", 7/16" & 1/2" sockets
• Tape measure
• Flathead screwdriver
• Chalk / chalk line

Installation Process — Build As You Go

The Sollega FastRack 510 (FR510-6) Hybrid (ballasted and/or anchored) racking solution is a 'build as you go' system. The FR510-6 ships with four bolts pre-installed in specific locations on the bucket, providing a 5°, 6°, or 10° tilt. It is engineered to install on flat roof (<7°) and ballasted ground-mounted PV solar arrays.

Lifting and Staging

Start installation on the far end of the roof opposite the roof loading (crane, all-terrain forklift) location. Pallet dimensions are 50" x 32" x 91" (1.27m × 0.81m × 2.31m) H, consisting of two stacks of 45 FR510-6's and weighing 470 lbs. When lifting to the roof, ensure pallets are strapped to the lift. The roof can be staged in single-pallet (20–25 kW) increments per the engineered layout.

Step 1: Build-as-you-go / Positioning

1. Measure the distance from the edge of the parapet and mark the required setback per engineered plans with a chalk line.
2. Position the first row of FR510-6s in alignment with the setback, building out racking, modules, ballast, and anchors as you go to keep the roof open for access.
3. Maintain a 3/8" gap between adjacent FastRacks, using a module and the reference tabs for spacing.
4. Maintain a fire access pathway of 4 ft minimum along the parapet.
5. Place one ballast block in the FR510-6's during initial placement to keep racking from moving.
6. Once the first row is positioned and all fasteners are tightened, install ballast per the Sollega-provided ballast schedule to lock the first row down.
7. Repeat the process row by row until the array is complete.

Slip Sheet Installation (Rooftop Only)

Follow the roofing manufacturer's guidelines. Slip sheets are cut to size of the specific roofing material (BUR, TPO, PVC, KEE, EPDM) and placed directly underneath the FR510-6's; they can be fixed or loose depending on roofing manufacturer guidelines. The FR-SlipSheet measures 1'-6" x 1'-8"; the FR510-6 footprint is approximately 1'-6" x 1'-3" wide by 1'-5" to 1'-8".

Step 2: Attach Clamps

1. Install the pull clamp (FR-PC) over the pre-installed bolts in the FR510-6, pushing the FR-PC out towards the edge of the FR510-6 completely.
2. Install the FR-EC end clamp over the bolt on top of the FR-PC.
3. Loosely install a serrated flange nut (FR-N) on the bolt, threaded on by hand — do not tighten yet.

Step 3: Affixing Modules to the FR510-6

1. Pull the FR-PC firmly against the bottom flange of the module.
2. Install the FR-EC and FR-N bolt.
3. Torque the FR-N to 8 ft-lbs (≈ 10.8 N·m, 96 in-lbs) using a 1/4" inch-pound click torque wrench.
4. Use the integrated 3/8" (9.5mm) spacers and module edge reference tabs on the FR510 to ensure proper module placement.
5. Mark the assembly with a paint marker once torqued.

Slide-On Bonding Jumper (FR-SBJ)

Slide-on bonding jumpers (FR-SBJs) are a one-time-use, East-West bonding solution rated to 35 amps. For E-W module-to-module bonding, simply pull the FR-SBJ onto the underside module flange of adjacent panels, placing it on the high side of the module. When replacing or removing modules, reattach using a new FR-SBJ. All bonding/grounding assemblies are UL 2703-compliant and must follow the installation procedures to satisfy NEC 690.43(A).

Row-to-Row Bonding Requirements

1. Attach an FR-SGB-4 Ilsco grounding lug to the underside of the module frame using a 7/16" socket torqued to 50 in-lbs.
2. Run #6 bare copper wire (N/S) through the other side and tighten with a 7/16" socket to 30 in-lbs.
3. Run the wire under the FR510-6 frame overhang, using FR-W-CLP clips for management.

Ballast Requirements & Arrangement

Approved roof pavers (ballast blocks or CMUs) dimensions are 16"L x 8"W x 4"H nominal (3 5/8" x 7 5/8" x 15 5/8" actual, ≈ 406mm L × 203mm W × 102mm) with an average weight of 32.5 lbs (13.5 kg) FULL, or HALF: 2" x 8" x 16" nominal (1 5/8" x 7 5/8" x 15 5/8" actual). Pavers should have a minimum net-area compressive strength of 3000 psi or must comply with ASTM Designation C1491. Each FR510-6 can hold a maximum of 5 full-size ballast blocks or 10 half-size blocks; follow the amount specified per FR510-6 by the project engineering.

Mechanical Anchor Installation

Mechanical anchors should be left placed loosely onto the roof until the array is fully installed. The Sollega-supplied anchor assembly (FR-MAA, P/N 240425) includes an aluminum L-foot with T-bolt, two aluminum L-feet with T-bolts, an Eco Standard aluminum rail (9 FT/108"/2740mm or 10 FT/120"/3050mm), carriage bolts, square washers, a fender washer, a nylon lock nut, serrated flange nuts, and a U-Anchor (U2000/U2400/U2600/U2800).

1. Loosely assemble all connections without fastening the anchor to the roof or flashing.
2. Once the anchor location is confirmed, secure the anchor to the roof using deck-appropriate screws (not supplied by Sollega) as specified in the project engineering packet.
3. Hot-air weld the flashing to the roof membrane. Install the L-foot and rail.
4. Torque the connection nut to 20–25 ft-lbs (≈ 27–33 N·m). The mechanical anchor is installed between two adjoining FR510-6 units.

Module-Level Power Electronics (MLPE) — Rock-It Clip 2.0

While the FR510-6's UL3741 certification means MLPEs will not be necessary in many cases, some situations require them. The Rock-It Clip 2.0 mounts micro-inverters or power optimizers to the module frame.

1. Locate the Rock-It Clip 2.0, the micro-inverter or power optimizer, and the section of module frame where it will be mounted.
2. Slide the Rock-It Clip 2.0 onto the lip of the micro-inverter or power optimizer.
3. Slide the micro-inverter or power optimizer into the opposite lip of the module frame.
4. Tighten the bolt to 12.5 ft-lb (17 Nm) using a 3/8" calibrated torque wrench to clamp the clip to the module frame and secure the device.
5. Ensure the clip lip is tight against the module frame and the device flange is firmly against the clip flange to prevent rotation during tightening.

Ground Mount Prep and Installation

FastRack 510-6dg ground mounts ship with no assembly required and install quickly. They achieve a ground coverage ratio of 1.7 acres/MW with a 500W module (80% GCR) and fit in a 53' shipping container. Minimal prep is required — the racking sits directly on most substrates (7° grade or less) with no heavy equipment or ground penetration required. Engineering and wet stamp are available in all 50 states, with fully ballasted 5°, 6°, and 10° tilt options.

1. Verify all sites with a civil engineer to ensure proper drainage and stability.
2. Clear the site of all vegetation and treat with herbicide.
3. Grade the site to be within a 0–7° slope.
4. Install a geotextile layer across the site to prevent organic growth.
5. Put down a layer of aggregate or road base for drainage (1/2" with a smaller 1/4" on top).