Lapp EPIC SOLAR 4 GEN2 Assembly Instruction Manual

The Lapp EPIC SOLAR 4 GEN2 is a high-performance solar cable management system designed for photovoltaic installations. This manual provides comprehensive instructions for safe and efficient assembly, including component identification, step-by-step installation procedures, connection guidelines, system configuration, maintenance, and troubleshooting. Ensure you read all safety warnings before proceeding.

1. Components Overview 2. Safety Precautions 3. Assembly Instructions 4. Electrical Connections 5. System Configuration 6. Mounting & Installation 7. Testing & Commissioning 8. Maintenance Guidelines 9. Technical Specifications 10. Warranty Information 11. Troubleshooting

Components Overview

Key components included: EPIC SOLAR 4 GEN2 Cable Tray Sections, Support Brackets, Connectors, Mounting Hardware, End Caps, and Splice Plates.

Component	Description
Cable Tray Sections	4-inch wide, UV-resistant polymer trays in standard lengths
Support Brackets	Stainless steel brackets for secure mounting
Connectors	Internal and external connectors for joining tray sections
Mounting Hardware	Stainless steel bolts, nuts, washers, and anchors
End Caps	Protective caps for tray ends
Splice Plates	Reinforcement plates for joining sections
Support Clamps	For securing cables within the tray
Expansion Joints	For accommodating thermal expansion
Grounding Kits	For proper system grounding
Identification Labels	For cable routing identification

Safety Precautions

Always follow electrical safety standards and wear appropriate PPE during installation.

De-energize all electrical circuits before beginning installation.
Wear safety glasses, gloves, and appropriate footwear.
Use proper lifting techniques when handling long tray sections.
Ensure mounting surface is structurally sound and can support the load.
Follow local electrical codes and regulations.

WARNING! Failure to follow safety procedures may result in serious injury or equipment damage. Only qualified personnel should perform installation.

Assembly Instructions

Follow these steps for proper assembly of the cable tray system.

Lay out all components according to your installation plan.
Install support brackets at specified intervals (typically every 4-6 feet).
Place first tray section onto support brackets and secure with provided hardware.
Connect subsequent sections using connectors and splice plates.
Install expansion joints where required for long runs.
Secure all connections with appropriate torque (15-20 ft-lbs).
Install end caps on all open tray ends.

CAUTION! Do not exceed the maximum span between supports. Ensure all connections are secure before loading cables.

Electrical Connections

Cable Capacity: Maximum fill ratio 40% of tray cross-sectional area.
Cable Types: Compatible with PV wire, USE-2, THWN-2 up to 600V.
Separation: Maintain separation between AC and DC circuits as per code.
Bending Radius: Maintain minimum cable bending radius during installation.
Grounding: Install grounding kits at both ends of each tray run.
Support Clamps: Use clamps every 24 inches for cable support.
Identification: Label all cables at entry and exit points.
Clearance: Maintain minimum 1-inch clearance around cables.

System Configuration

Plan your system layout before installation. Consider cable routing, expansion, and access requirements.

Layout Planning: Measure installation area, account for obstacles, plan support locations.

Expansion Considerations: Allow for thermal expansion (0.1 inch per 10 feet per 100°F).

Access Requirements: Ensure access points for cable pulling and maintenance.

Environmental Factors: Consider wind loading, snow accumulation, and UV exposure.

Mounting & Installation

Proper mounting ensures system longevity and safety.

Mark all mounting points according to your layout plan.
Drill holes for anchors if mounting to concrete or masonry.
Install support brackets using appropriate hardware for your surface.
Level all brackets before securing final torque.
Install tray sections, starting from fixed points and working outward.
Check alignment and level throughout installation.

Tip: Use a laser level for long runs to ensure proper alignment.

Testing & Commissioning

Verify installation before placing system into service.

Visually inspect all connections and hardware.
Check torque on all bolts and connections.
Verify proper grounding continuity (less than 1 ohm resistance).
Test cable tray for structural integrity (no excessive deflection).
Install cables according to planned routing.
Perform insulation resistance test on installed cables.
Verify proper cable support and clamping.
Document installation with photos and notes.

WARNING! Do not energize system until all testing is complete and documented.

Maintenance Guidelines

Regular maintenance ensures optimal performance and safety.

Quarterly: Inspect for physical damage, loose hardware, corrosion. Annually: Clean debris, check grounding connections, verify cable condition. After severe weather: Inspect for damage, check alignment, verify structural integrity.

Technical Specifications

Material: UV-stabilized polymer composite
Width: 4 inches (100mm)
Depth: 2 inches (50mm)
Lengths: 6ft, 8ft, 10ft standard sections
Temperature Range: -40°F to 185°F (-40°C to 85°C)
Load Capacity: 50 lbs/ft distributed load
UV Resistance: 20+ years outdoor exposure
Flame Rating: UL94 V-0
Color: Solar Gray (standard)

Warranty Information

Lapp warrants the EPIC SOLAR 4 GEN2 system against defects in materials and workmanship for 25 years from date of purchase when installed according to these instructions. This warranty covers replacement of defective components but does not cover improper installation, misuse, or damage from external causes. For warranty claims, contact Lapp Customer Service with proof of purchase and installation documentation.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Tray sagging between supports	Excessive span or overload	Add intermediate supports; reduce cable load.
Connections coming loose	Insufficient torque or vibration	Retorque to specification; install locking hardware.
Cable damage	Sharp edges or improper clamping	File smooth edges; install proper clamps.
Poor grounding continuity	Corrosion or loose connections	Clean contact surfaces; tighten connections.
Material cracking	Impact damage or over-torquing	Replace damaged section; use torque wrench.
Alignment issues	Improper support placement	Adjust supports; realign sections.
Water accumulation	Improper slope or blocked drainage	Ensure minimum 1/4" per foot slope; clear debris.

Technical Support: 1-800-LAPP-USA (1-800-527-7872); www.lappusa.com

Emergency Contact: For immediate assistance with critical installations.